June 2020

Trends and Resources

Innovations

Sphera has released a new Interactive piping and instrumentation diagram (P&ID) solution that helps organizations break down silos between their operations, maintenance and engineering departments while simplifying isolation planning.

Interactive P&ID solution

Sphera has released a new Interactive piping and instrumentation diagram (P&ID) solution that helps organizations break down silos between their operations, maintenance and engineering departments while simplifying isolation planning.

For decades, companies—especially those in hazardous industries—have used P&IDs to help map out potential risks from pressure, temperature, hazardous materials, etc. P&IDs are important to perform during times when certain processes must be “isolated” for maintenance and other types of work.

The new Interactive P&ID augments Sphera’s Control of Work offering by helping companies better plan and manage the safe execution of isolation activities, such as removing hydrocarbons or other hazardous energies (hydraulic, pneumatic, chemical, electric, etc.) from pipes, tanks, vessels and mechanical equipment so that work can be done safely on a part or section of the plant.

Available on SpheraCloud, an SaaS-based and mobile platform, the Interactive P&ID software (FIG. 1) allows users to upload their PDF schematics and mark up the electronic document with actions, rules and isolation points. This data is then automatically carried into the integrated isolation planning process.

The Interactive P&ID software allows engineering, maintenance and operations to collaborate on isolation planning and provide operational feedback to engineering. In addition, it systematically captures the Management of Change (MoC) process. This promotes continuous improvement in the quality of the P&ID and can eliminate rework by automating plans.

Radiation-less, in-tank inspection

Finnish company Rocsole Ltd. is featuring its award-winning, patented Liquid In-Tank Inspection (LITI) product. Tomographic imaging has not been commonly used in the industry for scanning vessels for water, oil, emulsion or gas layers.

The Rocsole solution brings various benefits. With the LITI product, it is possible to provide full profiles of vessels with no radiation. This means it is safe for both the environment and the user. The product also brings continuously valuable and trustworthy data of tanks and separators, even in very challenging conditions. This gives an advantage in optimizing production in multiple ways.

The LITI Tank Profiler works as well as nucleonic devices, but without the typical associated cost and risks. Additionally, it provides continuous real-time data, meaning that it provides AI-powered predictive analytics for these sub-processes with the company’s capabilities. The LITI Tank Profiler main features are:

• Accurate detection of location, thickness and conductivity of different layers
• Works with gases, liquids, emulsions, sludge and solids
• Continuous data, real-time monitoring
• Works even with contaminated sensor surfaces
• Easy to install, safe to operate, has no moving parts and is field calibration-free
• Images and trends available through a web-based user interface.

The services are preferably offered as a software-as-a-service (SaaS) model.

High-speed TDLS analysis

Yokogawa Corp. of America has released the TDLS8100 probe-type Tunable Diode Laser Spectrometer (TDLS), shown in FIG. 2. Industrial process heating operations (fired heaters, boilers and furnaces) account for approximately 70% of the manufacturing sector’s process energy consumption and constitute a major process safety risk and source of greenhouse gas emissions. The TDLS 8100 enables operators to make a step change in safety improvements, emissions reductions, optimization of fuel efficiency and yields, as well as prolong the life of their assets.

A flagship product in Yokogawa’s OpreX Analyzers lineup, the TDLS 8100 makes quick and accurate in-situ gas concentration measurements, eliminating the requirement for sampling and conditioning components. This results in reduced installation and maintenance costs. The instrument is field-serviceable with no consumables or calibration required. The single-flange design allows installation where cross-duct TDLS technology was previously infeasible due to accessibility, obstructions or budget constraints.

The energy and chemical industries must embrace triple-bottom-line performance to drive sustainability targets and outcomes. This involves placing equal importance on people, the environment and profits to drive sustainability outcomes that are existential to everyone. The TDLS 8100 makes plants significantly safer, improves resource efficiency, reduces air emissions and contributes to enhanced asset profitability.

For use in safety instrumented systems, the TDLS8100 analyzer is SIL2 compliant. It is also explosion-proof for Division 1 and Zone 1 installations.

Connecting Modbus RTU devices to a wireless network

Fieldbus International (FINT) launches an easy-to-use, straightforward solution for connecting Modbus RTU devices to a wireless network, for example in Industrial Internet of Things (IIOT) applications.

FINT is a market leader in fieldbus communications technology and has launched its new DIN rail-mounted Wireless Hart adapter with Modbus RTU interface, model T910. Together with its embedded version of the adapter, model T810, which is tailored for battery operation, these advanced Fint products provide unmatched performance and support for connecting Modbus devices to WirelessHART networks.

The user simply specifies up to eight variables (floating-point or integer), the status signals, the tag name, Wireless-HART network join credentials (Network ID and Join Key).

When the device is installed and powered up, it automatically scans for and joins the WirelessHART network, and then starts communicating, providing a “plug and play” solution to the end user for what is potentially a complex problem.

Augmented technology improves field operator experience

ABB has launched ABB Ability™ Augmented Field Procedures to drive worker safety and efficiency across the energy sector. The company has developed an innovative augmenting technology aimed at digitalizing the field operator experience (FIG. 3) and improving interaction between field and control room operations.

With more than 20% of industrial downtime reportedly due to human error, ABB Ability Augmented Field Procedures will enable consistency when executing manual procedures, standardizing operating procedures and maintenance or repair techniques in the field, tightening field-to-control room integration and digitally recording notes to ensure operational knowledge is captured and utilized.

Unlike traditional paper-based operating procedures, the technology enables interactive execution of procedures, using a mobile device to guide operators through each step in a consistent, effective and safe way.

Operatives will be able to access hands-free, real-time data related to plant assets, processes or procedures using industrial tablets, smart phones and Microsoft HoloLens glasses, increasing real-time collaboration and enabling immediate data entry from the user interface in the field.

The system can be used in any industrial environment across the oil, gas, chemical, process, power and water sectors.

Intrinsically safe smartphone for demanding industrial applications

Pepperl+Fuchs ecom, a leading manufacturer of explosion-proof mobile devices, has received certification for its intrinsically safe Smart-Ex® 02 smartphone for Zone 1/21 and Div. 1. The device is the first to receive Google’s Android Enterprise Recommendation.

As plant networking and the demand for mobile solutions increase, the Android Enterprise Recommended standard makes the search for the right mobile solutions easier. It provides a list of devices and services verified according to Google’s strict enterprise requirements. These solutions meet the highest standards for industrial use and have been designed and tested by Google.

Android Enterprise Recommended ensures consistent, easy deployment and management of the mobile solutions through hardware and operating system support, guaranteed Android upgrades and regular security patches. In addition to time and cost savings in the supply and maintenance of the devices, users benefit from close collaboration between Google and the manufacturers and comprehensive manufacturer support services. This can include quality control in Germany and global support from Pepperl+Fuchs ecom.

Designed for a temperature range of –20°C–60°C (–4°F–140°F), the Smart-Ex 02 can even be used in extreme conditions. The rugged, impact- and scratch-resistant Gorilla® Glass display is easy to read, even in direct light. A powerful, replaceable, 4400-mAh battery enables coverage of 24-hr shifts. The magnetic USB port protects against wear and damage to PINs and weak USB connections.

Cloud-connected radar level sensor

Endress+Hauser has launched the Micropilot FWR30, its first cloud-connected radar, to provide full transparency in the storage and transport of liquids. As the world’s first 80-GHz wireless IIoT sensor, it combines high-end technology and user-friendly digital services in one cost-effective device. The instrument’s continuously recorded measurement data can be accessed at any time, from anywhere, due to the device’s cloud connection, with communication made possible by an integrated SIM card.

Installation is easy and can be done in less than three minutes. An integrated battery allows operation without an external power supply, a particular advantage for measuring points that are difficult to access. This compact device is a good fit for stackable tanks and enables a plug-and-play solution for flexible and easy installation.

In addition to the measured level, users receive information on the location of their storage tanks and containers via the cellular communication system. The instrument provides facts where previously only assumptions were possible, helping users optimize logistic and storage processes and save valuable time by providing continuous and easy access to inventory information.

The Micropilot FWR30 (FIG. 4) can be used for level measurement and inventory management of mobile and stationary plastic tanks. In addition, the tracking of mobile storage tanks is also possible. The free radiating measuring device covers measuring ranges up to 50 ft and temperatures between –4°F and 140°F (–20°C–60°C). Since it uses non-contact measurement, the Micropilot FWR30 can be used in all liquid media. It is resistant to corrosion, abrasion, viscosity or toxicity and can be used in a variety of industries.

Depending on individual requirements, users can choose from a broad portfolio of services, including Netilion Value and SupplyCare Hosting. All digital software applications can be used on various end devices, such as desktop, tablet or smartphone, and comply with the highest security and data protection requirements.

Vacuum pumps for mass spectrometer systems

Pfeiffer Vacuum showcases Hena 50 and Hena 70 powerful vacuum pumps for mass spectrometer systems.

• Single-stage, oil-sealed rotary vane pumps
• Backing pump for mass spectrometers and similar applications
• Ideal for laboratory use, sturdy and reliable.

Hena 50 and 70 (FIG. 5) are single-stage, oil-sealed rotary vane pumps that were specially developed for the demanding requirements of mass spectrometer systems. They achieve pumping speeds of between 32 m³/hr and 59 m³/hr, depending on their size and speed of rotation. Their integrated oil mist separator ensures clean exhaust air. They are equipped with a frequency converter that enables them to be used worldwide with single-phase input and identical pump capacity for 50 Hz and 60 Hz.

A constantly high flowrate in the target pressure range, adjustable pumping speeds and low final vacuum contribute to the instrument’s reliable high performance. Long maintenance intervals and operating hours are ensured by the high oil volume in the pumps and their low oil temperature during operation.

Hena 50 and 70 can increase the overall availability of the instrument through their high ruggedness and reliability. At the same time, they are easy to integrate due to their low noise level and efficient oil separation. Both Hena 50 and Hena 70 are certified according to UL and IEC 61010.

ATEX-certified bolting and pipeline tools

Enerpac has introduced a complete suite of ATEX-certified tools for engineers working in potentially explosive atmospheres. Suitable for Zones 1 and 2 gaseous atmospheres and Zones 21 and 22 dust atmospheres, the range includes hydraulic torque wrenches, air pumps, flange spreading tools, hydraulic sealed hand pumps and hoses.

Compliant with EN ISO 80079:2019 parts 36 and 37, the Enerpac certified tools (FIG. 6) are one of the largest ranges of ATEX-certified tools available today. By providing both tools and ATEX-certified hydraulic hoses, Enerpac enables a safer approach to projects in potentially explosive atmospheres.

The Enerpac ATEX-certified tools include the S-Series Square Drive torque wrenches, W-Series low-profile hexagon wrenches, W-Series ultra-slim bi-hexagonal cassettes and the aluminum DSX-Series Square Drive torque wrenches. In addition to the ATP-Series ultra-high-pressure, general purpose air pump, the range features the ZA4T-Series air-driven torque wrench pump and XA-Series air-driven foot pump. Other tools in the range are the SWI-Series flange spreading tool kit, HP-Series hand pump kits and 144-Series ATEX hydraulic hoses up to 6 m.

The Enerpac ATEX-certified tools are included within the general hydraulic tools catalogue and can be used for both ATEX and non-ATEX related projects. In this way, companies faced with occasional ATEX projects are able to respond quickly and effectively without the need to procure additional ATEX tools.

Plug-in, easy-test terminal blocks

Dinkle Intl. has made available its DPT DIN rail disconnect terminal blocks (FIG. 7) to provide efficient, safe disconnect and testing of current transformer (CT) and voltage transformer (VT) circuits, which are used in industrial automation applications across many sectors.

CTs and VTs isolate a primary power feed from a secondary circuit, permit grounding of the secondary circuit, and step-down the current or voltage to an appropriate level for measurement. Terminal blocks are then used as the termination points for instrument loops on the secondary circuit.

Panel builders have traditionally incorporated barrier-type terminal blocks in CT circuits; however, these are challenging to access, require proper tools, and take time for backplane mounting and screw-down wire terminations. Additionally, there is always the danger of under-torqueing and loose wiring connections, or over-torqueing and stripped screw threads.

Dinkle’s DPT DIN rail series terminal blocks address these issues by providing easier access, DIN rail mounting with no tools required, and push-in design to ensure secure wiring connection while reducing time and tools required for termination.

The DPTD6 model block also provides direct-testing technology, enabling a user to test the circuit current without undoing any wired connections. To perform direct-test for a single- or three-phase circuit, the user switches a lever on the terminal block to disconnect a de-energized circuit. The user then places a current-measuring device across the block at its test points, using either 4-mm test probes or securely fastened 2.3-mm test plugs. The DPTL6 model version is similar to the DPTD6 but without a disconnect lever for testing.

Both blocks are UL rated up to 30 amps at 600 VAC. The blocks are DIN rail mountable and measure 8 mm in width by 103.2 mm in height by 50 mm–57.5 mm in depth (depending on DIN rail depth), allowing for easier installation and space saving compared with traditional barrier-type terminal blocks.

These push-in style blocks accommodate wire sizes from AWG20 to AWG8, and also feature plug-in slots for bridges (jumpers), providing reliable continuity between any combination of blocks on the same DIN rail. They are completely touch-safe—back of hand and finger protection—and operate at temperatures from –40°C–120°C (–40°F–248°F).

Users can employ these DPT series blocks to safely disconnect secondary circuits between measuring instruments and safety equipment in CT shorting and other applications. A safe disconnect can be achieved by placing the block in front of the measurement instrument.

Dinkle provides a complete product line of DIN rail terminal blocks to complement the DPT series, including but not limited to power distribution, sensor/actuator, diode embedded and pluggable fuse blocks. The company’s products carry safety approvals including UL, CUL, CSA, VDE and GB. The material used for manufacturing is compliant with RoHS and REACH environment standards set by the EU.

Gas monitor provides detection for light industry

Facilities and plant engineers will find that the next-generation TG5000 Gas Monitor (FIG. 8) from MSA Safety offers a safe, reliable and effective solution to the detection of oxygen, combustible and toxic gases in a wide range of light industrial applications, including industrial plants, wastewater treatment, and commercial buildings.

The feature-rich TG5000 gas monitor helps personnel work safely and with confidence in an extensive number of environments, offering a variety of gas sensor options and installation configurations. The modular, single- or dual-sensor mechanical design offers application flexibility and helps reduce wiring costs. The intuitive design of the local interface makes it simple to install, use and maintain. The organic LED (OLED) multilingual display and bright LED indicators show the instrument status (power, fault or alarm), the gas readings and its Bluetooth connection. A touch-button interface provides tool-free, rapid access to all instrument settings and functions.

Highly flexible, the TG5000 monitor can operate on a completely standalone basis with its large LCD display, quick-check LEDs, and four relay outputs (three alarm and one fault), or can be connected with a 4-20 mA output to a control system (PLC, DCS, etc.). Digital HART communication is also available. The unit can also be configured for remote monitoring applications, where the installation area requires that the sensor be separated from the electronics. The TG5000 includes a 95-dB audible alarm with horn silence control. Optional accessories include a sunshield and a strobe light kit.

The TG5000 features MSA’s advanced XCell® Sensors, which respond rapidly and reliably to leaking gases to help protect people, equipment and facilities. The TG5000’s best-in-class XCell Sensors include MSA’s innovative TruCal® technology that achieves lower drift for superior sensor stability and performance. The result is longer sensor life with longer calibration cycles—up to 18 mos for hydrogen sulfide (H₂S) and carbon monoxide (CO)—that require fewer maintenance technician hours, which lowers overall sensor lifecycle costs while maintaining effective protection levels.

The advanced design of the XCell TruCal sensors also features highly advanced self-diagnostics. These intelligent sensors detect potential failures or maintenance needs without applying calibration gas, compensate for sensor drift due to environmental changes and notify users if the gas sensor becomes blocked. These rugged sensors operate over a wide temperature range from –40°C–60°C (–40°F–140°F). Built-in SafeSwap™ capability enables the quick replacement of XCell sensors without turning off the instrument for simplified maintenance.

The TG5000 is available with a helpful Bluetooth interface that connects with MSA’s X/S Connect App for Apple iOS or Android platforms. Workers will appreciate the safety of wirelessly accessing the gas monitor up to 75 ft (23 m) away, using the smartphone or tablet of their choice.

In addition to combustible gases and oxygen deficiency/enrichment, the TG5000 is designed to monitor a wide range of toxic gases: carbon dioxide (CO₂), CO, chlorine (CL), hydrogen (H₂), H₂S, nitrogen dioxide (NO₂) and sulfur dioxide (SO₂). These sensors, depending on the gas, are designed with state-of-the-art infrared or electrochemical technologies.

The TG5000 Gas Monitor meets a wide variety of industrial facility gas detection needs. To enable personnel to work safely in these environments, monitoring of toxic gases, oxygen enrichment and deficiency, and combustible gases is an absolute necessity.

Condition monitoring field device

Brüel & Kjær Vibro has launched its next-generation VCM-3 condition monitoring platform (FIG. 9) for a wide range of industries. The VCM-3 is designed to increase the uptime and reduce overall lifecycle costs of pumps, fans, motors, gearboxes and many other types of machines, while increasing reliability.

The field-proven VCM-3 is a 12-channel data acquisition hub targeted at full featured monitoring of auxiliary machines, balance-of-plant (BOP) non-critical machines and other assets in industries where cost-effective condition monitoring is required without machine protection. It features enhanced condition monitoring measurement techniques, easy system integration, built-in cybersecurity and simple IT solution installation.

Users with all levels of in-house monitoring expertise can operate the platform’s diagnostic tools. Key benefits of the platform include:

• Simultaneous input channels with high sampling frequency
• Very easy to install
• Robust cybersecurity
• Internal (device) OPC UA server and storage.

A worldwide network of sales and service offices and partners supports the VCM-3. HP

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