Botlek Studiegroep

Botlek Studiegroep
Gerard van Boven
2012-06-14
Process instrumentation and measurement solutions
Maintenance “from the cradle to the grave”
1. KROHNE – brief introduction
2. Design, development
3. Production, calibration
4. Installation, commissioning
5. Operation
6. Maintenance
7. Conclusion
Title here
24 max. one line
“From
the again
cradleintoArial
the grave”
Agenda
Maintenance
Why is it needed?!?
3 | Botlek Studiegroep | June 14, 2012
1. KROHNE – brief introduction
2. Design, development
3. Production, calibration
4. Installation, commissioning
5. Operation
6. Maintenance
7. Conclusion
Title here
24 max. one line
“From
the again
cradleintoArial
the grave”
Agenda
Design, development
Well thought of in advance
•
Materials
•
Construction
•
Backwards compatibility
=
5 | Botlek Studiegroep | June 14, 2012
2
mc
Quality
Design, development
Materials, construction
•
Injection moulding
•
PFA
•
PP
•
Stainless steel mesh
•
Dovetail groove
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Design, development
Ceramics
• Most reliable & robust material available
• Long term stability under toughest conditions
• Extremely resistant against corrosion and abrasion
• Robust & form stable
• Design suitable for easy & quick installation
• Leak tight
• Absolutely vacuum resistant
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Design, development
Ceramics – unique design
• Measuring tube with typical
conical shape
• Improves flow profile
• Accurate measurement under
tough process conditions
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Design, development
*) ceramic = Al2O3 or ZrO2
metal = Platinum
CERMET = CERamic + METal*
CERMET-electrode production
Platinum powder
preparation
forming
rasterscan microscope recording
ceramic powder
preparation
mixing
12 µm
insertion
sintering
ceramic = dark
Platinum = light
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Design, development
Backwards compatibility
•
Transmitter mostly weakest link
•
Electronics fail earlier than mechanics
•
Adding new- or other functionality
•
New transmitter on old/other sensor
•
Mechanical adaptation – if required
•
Basic functionality guaranteed
•
Back to 1972
10 | Botlek Studiegroep | June 14, 2012
1. KROHNE – brief introduction
2. Design, development
3. Production, calibration
4. Installation, commissioning
5. Operation
6. Maintenance
7. Conclusion
Title here
24 max. one line
“From
the again
cradleintoArial
the grave”
Agenda
Production, calibration
Delivery of what has been requested
•
Production segments
•
Qualified/certified personnel
•
Quality control
•
Wet calibration
Performance
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Production, calibration
The man behind the machine
•
Little automation
•
Short production routing
•
Small production steps
•
Check after each step
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Production, calibration
Quality control to control quality
•
ISO 9001
•
ISO 14001
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ISO 17025
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ATEX
•
OIML, MID
•
RvA
14 | Botlek Studiegroep | June 14, 2012
Production, calibration
Initial verification
•
Wet calibration without exception
•
Water, air, oil, gas
•
Standard, customized
•
RvA
•
OIML, MID
15 | Botlek Studiegroep | June 14, 2012
Production, calibration
Costs of 0,25%
Example – 12” gas flowmeter
•
ID = 303 mm
•
P = 50 bar
•
V = 15 m/s
•
Z = 0,89 (20°C)
•
costs = € 0,10/Nm3
Measurement area clean: π/4 * ID2 = 0,072 m2
Flow per second: (0.072 * 50 * 15) / 0,89 ≈ 60 Nm3/s ≈ € 6,00/s
Per year this is 6 * 60 * 60 * 24* 365 ≈ € 190.000.000,00
0,25% uncertainty is 0,0025 * € 190.000.000,00 ≈ € 475.000,00/year
16 | Botlek Studiegroep | June 14, 2012
1. KROHNE – brief introduction
2. Design, development
3. Production, calibration
4. Installation, commissioning
5. Operation
6. Maintenance
7. Conclusion
Title here
24 max. one line
“From
the again
cradleintoArial
the grave”
Agenda
Installation, commissioning
Locating best location
•
Site survey
•
Technical data sheet
•
Customized settings off factory
•
Quick start
•
Assistance during commissioning
Plug & play
18 | Botlek Studiegroep | June 14, 2012
1. KROHNE – brief introduction
2. Design, development
3. Production, calibration
4. Installation, commissioning
5. Operation
6. Maintenance
7. Conclusion
Title here
24 max. one line
“From
the again
cradleintoArial
the grave”
Agenda
Operation
Measurement including self-diagnostics
•
Indication by instrument
•
Reducing maintenance intervals
•
Better insight in required maintenance
•
Trend visibility
Confidence
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Operation
On site indication
•
Graphical display
•
Actual measured values, dimensions
•
Status
•
Diagnostic information
•
Multimeter
•
PACTware
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Diagnostics
In general, KROHNE flowmeters are:
•
field proven
•
very reliable
•
maintenance free
Improved availability provides certainty even in difficult applications
Continuous verification of instrument
functionality in application
“Pro-active maintenance means cost savings”
22
Diagnostics
What?
Diagnosis of application
•
information by various field instruments
application
Diagnosis of installation
•
process diagnosis/application check
•
performed in instrument or external
installation
Diagnosis of flowmeter
•
self test performed in instrument
flowmeter
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Diagnostics
Why?
Possible causes of malfunctioning
•
change of process conditions
•
cavitation
•
over-temperature & vacuum
•
incorrect installation
•
impropriate materials
•
abrasion through solids
•
scaling/fouling
•
external magnetic fields
•
defective instrument components
•
…
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Diagnostics
Information available
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Diagnostics
KROHNE Care
26 | Botlek Studiegroep | June 14, 2012
1. KROHNE – brief introduction
2. Design, development
3. Production, calibration
4. Installation, commissioning
5. Operation
6. Maintenance
7. Conclusion
Title here
24 max. one line
“From
the again
cradleintoArial
the grave”
Agenda
Maintenance
Back on the right track
•
Field verification
•
Recalibration
•
Replacement
•
Mechanical, electronical
Reliability
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Maintenance
Field verification
•
(Software) tools
•
Simulator
•
Trend visualization
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Maintenance
Recalibration
•
Zero calibration
•
Dry calibration
•
Prover
•
Wet calibration
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Maintenance
Replacement
Sensor
•
Complete
•
Parts
Transmitter
•
Complete
•
Parts
Complete instrument
31 | Botlek Studiegroep | June 14, 2012
1. KROHNE – brief introduction
2. Design, development
3. Production, calibration
4. Installation, commissioning
5. Operation
6. Maintenance
7. Conclusion
Title here
24 max. one line
“From
the again
cradleintoArial
the grave”
Agenda
Conclusion
Maintaining (initial) requirements
Affected by every step in circle of life
Peace of mind
•
user is informed should something be wrong
Costs savings on maintenance
•
reduce periodic maintenance of instrumentation
•
reduce checking of suspicious flow meters
Costs savings on plant operation, avoiding
•
malfunctioning instruments
•
unforeseen breakdown of instruments
33 | Botlek Studiegroep | June 14, 2012
Trust
Botlek Studiegroep
Gerard van Boven
2012-06-14
That’s it… what’s next?!?