ERTC 2023
Reduce maintenance and calibration intervals with accurate instruments and analysis systems
Sophia Asal Endress+Hauser
European refiners are grappling with com- plex challenges related to environmental regulations, changing market dynamics, and global competition. To remain com- petitive and sustainable in the face of upcoming investment in emission-reduc- ing technologies, plant uptime, efficiency, process safety, and cost optimisation have never been more important. Introduction The efficient operation of refineries involves an intricate set of processes and chal- lenges: meeting stringent product qual- ity standards and specifications to comply with regulations and customer expecta- tions, securing a reliable and cost-effective source of feedstock, and managing energy consumption – to name just a few. Moreover, the refining process itself is highly complex, and its various unit opera- tions, like distillation, cracking, reforming, and blending, require continuous optimi- sation for efficiency and product quality: an ever-ongoing operational challenge. With high uptime and availability as well as safe and reliable operation being of utmost importance, downtime for maintenance is costly, so scheduling and executing mainte- nance activities efficiently is crucial. The importance of accurate measurement Reliable process measurement equipment is vital for the plant’s safe operation: it ensures product quality, safety, and operational effi- ciency by closely monitoring key variables like temperature, pressure, and composition. Measurement devices help optimise pro- cesses, improve energy efficiency, and ensure compliance with environmental reg- ulations. Additionally, they enable predictive maintenance, resource management, and data-driven decision-making, enhancing over- all plant performance and cost-effectiveness. To effectively address operational chal- lenges and ensure optimal uptime, it is essential to collaborate with an experi- enced partner. The process measurement device manufacturer of your choice should have in-depth industrial know-how, a deep understanding of your process require- ments, and a well-established global net- work of trained personnel. Liquid analysis competence for Gas-to- Liquid plants When it comes to gas-to-liquid (GTL) plants, the requirements to be considered are simi- lar to those of traditional refineries but also comprise challenges related to the specific GTL conversion processes. Liquid analy- sis plays a pivotal role in GTL plants during and after the conversion of gases into liquid hydrocarbons. This crucial process involves continuous monitoring and analysis of various liquid com- ponents and parameters to ensure the pro- duction of high-quality synthetic fuels and specialty chemicals by meticulously tracking product purity, composition, viscosity, and
Refineries must meet standards and specifications along with complying with regulations
Measurement devices optimise processes
reduce calibration intervals significantly by installing reliable, robust components and enhancing process insights. benefits of Device Type Managers A DTM is a crucial software component in industrial automation and process con- trol systems, facilitating the interaction with field devices using digital communica-
density. Moreover, liquid analysis sensors and instruments enable real-time monitoring of chemical reactions, aiding in reaction optimi- sation and catalyst management. Detecting and quantifying impurities and contaminants, optimising process conditions, and maintaining environmen- tal compliance are all key functions of liq- uid analysis. It also contributes to safety by promptly identifying hazardous conditions, and its data logging and automation inte- gration features enhance operational con- trol and decision-making. Curbing maintenance intervals For a major project in a GTL plant, Endress+Hauser was chosen to retrofit the existing large analyser base with Liquiline CM42 transmitters for accurate pH/ORP, conductivity, and dissolved oxygen meas- urement. The Liquiline CM42 transmitter is ideally suitable for demanding environments. Its intuitive operating concept simplifies commissioning, handling, and maintenance, saving operators time every day. It allows for easy switching of parameters and seamless system integration to facilitate the flexibility to adapt it to the specific meas- uring task. Another project assignment was the development of a Maintenance Device Type Manager (DTM) covering system con- figuration, diagnostics, performance calcula- tions, and calibration information in addition to the regular health check. The goal was to
perform calibration, and retrieve diagnos- tic data while providing a user-friendly graphical interface for operators. DTMs are device-specific, ensuring compatibility, and often incorporate security features to safe- guard against unauthorised access. DTMs provide a centralised remote access point for horizontal and vertical data flow, allowing for a safer work environment by reducing the number of trips to the field and lowering start-up and commissioning costs. By streamlining device management and enhancing reliability, DTMs play a key role in optimising industrial processes. Effective cost reduction During the assessment and the DTM design phase, all involved parties worked together in close collaboration. Customer require- ments for the DTM comprised, among oth- ers, the calculation and visualisation of key performance indicators, such as mean time before failure (MTBF), mean time to repair (MTTR), mean time between calibration (MTBC), and the resulting availability. The Memosens 2.0 platform of digital sensors, in combination with the visuali- sation of the key performance parameters via the DTM, gives the operators full trans- parency and reliable, accurate process insights. By trending the calibration results of the Liquiline CM42 transmitters through visualisation by means of the DTM on the plant’s existing DCS system, a possible extension of the calibration intervals from four to eight weeks was feasible. The benefits and value for the customer include the highest availability of installed Liquiline CM42 analysers, safe calculation of operational costs, clear and simple visu- alisation of key information for the opera- tors in the PLC room, less time in the field and, therefore, more personnel safety, pro- longed calibration intervals due to pre- dictive maintenance functionalities with access to a history of adjustments, higher reliability of the measured values, and neat documentation. All in all, extending the cal- ibration cycle by four weeks can reduce maintenance costs by 50% per year.
did you know? Reliable process measurement equipment is vital for the plant’s
tion protocols like HART or FOUNDATION Fieldbus. DTMs serve as the interface between the control system software and field devices, enabling configuration, real- time monitoring, diagnostics, and asset management. They allow engineers to set parameters, safe operation: it ensures product quality, safety, and operational efficiency
Contact: sophia.asal@endress.com
Process insights help to reduce calibration intervals
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