Control System World

exida, the global leader in functional safety certification for the process industries, has certified the Rosemount 5300 Series Guided Wave Radar Transmitter for functional safety, ensuring that it meets the functional safety requirements for Safety Integrity Level (SIL) 3 capability per IEC 61508: 2010.

“Rosemount’s capabilities were confirmed through an extensive certification process that included the completion of a Failure Modes, Effects and Diagnostic Analysis (FMEDA),” says Dave Butler, exida Evaluating Assessor. “Their mature development process provides the rigor needed to ensure the delivery of products that achieve high levels of functional safety.”

“We were confident in choosing exida as our certification body for their technical expertise in functional safety certification,” says Dajana Prastalo, Manager Product Approvals at Rosemount Tank Radar. “They have a rigorous process that gives our customers a solid confidence that our products are applicable to safety critical applications.”

The Rosemount 5300 Series is our superior 2-wire Guided Wave Radar (GWR) for challenging level and interface measurements on liquids, slurries and solids. It leverages our 30 years of proven radar expertise and is designed to focus on your plant’s profitability. The 5300 delivers everything you would expect from a best-in-class process radar – superior reliability, state-of-the-art safety features, effortless handling, and unlimited connectivity.

Features include:

Direct Switch Technology enables a stronger signal than other 2-wire GWR transmitters, providing better measurement capability and reliability.

Probe End Projection allows for measurement on very low dielectric products over long ranges.

Improved EMC performance with a Smart Galvanic Interface increases safety.

Easy integration into new or existing plants with a choice of 4-20 mA with superimposed HART, modbus output, or FOUNDATION ™ fieldbus with extensive support for PlantWeb® Alerts.

Powerful and easy-to-use configuration tools.

A wide range of probe styles to cover virtually any applications including extreme temperature and pressure probes for demanding environments.

Robust modular design and MultivariableTM transmitter resulting in low cost and increased safety.

Virtually unaffected by application conditions such as dust, vapor and interfering obstacles.

Rosemount 9901 – high quality chambers for process level instrumentation

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Yokogawa Electric Corporation has announced that its subsidiary, Yokogawa América do Sul Ltda., has received an order to supply the control system and field instruments for the São Miguel dos Campos second-generation bioethanol plant.

This plant will have a production capacity of 82 million liters per year and is being constructed by GranBio*1 in São Miguel dos Campos, a town in Alagoas state (northeast Brazil). As opposed to first-generation facilities that produce bioethanol from food products such as corn and sugarcane, this plant will rely on second-generation non-food sources such as woodchips and straw. São Miguel dos Campos is the first plant of its type to be constructed in the southern hemisphere, and it will be one of the world's largest such facilities, in terms of production capacity. It is scheduled to start commercial operation in early 2014.

As the main automation contractor (MAC)*2, Yokogawa América do Sul has been involved in this project from the FEED stage, performing the basic design for a control system and field instrumentation solution that will reduce costs and improve production efficiency throughout the lifecycle of the plant. Yokogawa will supply the CENTUM® VP integrated production control system to control plant facilities such as reaction tanks and distillation units, and a variety of field instrumentation and equipment including FOUNDATIONTM fieldbus*3 enabled ADMAG AXF magnetic flowmeters, DPharp EJA series pressure/differential pressure transmitters, and control valves. Yokogawa América do Sul will be responsible for delivery, engineering, and operator training.

Satoshi Yoshida, the President of Yokogawa America do Sul, comments as follows: “Brazil is a dominant player in the bioethanol market, second only to the United States. The biofuel market is steadily growing, and second-generation biofuel is attracting attention as an environmentally friendly energy source. Utilizing its accumulated control and instrumentation experience and know-how, Yokogawa will capitalize on the vast opportunities for growth in the renewable energy sector, a key target industry. In its role as a main automation contractor, Yokogawa will provide the latest plant control solutions and project execution services to the renewable energy sector in Brazil and other markets, and thereby work for a more sustainable future.”

Rockwell Automation has announced the Safety Maturity Index (SMI) tool, a self-guided assessment that gives manufacturers visibility into the effectiveness of their safety programs and the ability to optimize plant performance. Applicable to any industry, any plant size and any location in the world, the SMI tool helps manufacturers see where they measure in safety culture, compliance and capital. Most importantly, it provides recommendations to help achieve best-in-class safety performance.

The three principal components of a successful safe workplace – culture (behavioral), compliance (procedural) and capital (technical) – are equally critical and interdependent in developing a strong, sustainable safety program. For example, creating and maintaining a robust safety culture but not investing in safety technologies and/or complying with standards lowers a company’s ability to provide a safe workplace. Likewise, the possibility of risk remains when manufacturers invest in safety technologies but fail to emphasize the importance of safety culture throughout the organization.

Each safety pillar is measureable in the SMI tool using four categories – SMI 1: minimizing investment, SMI 2: attaining compliance, SMI 3: cost avoidance and SMI 4: operational excellence. By answering a series of questions, manufacturers can complete the SMI assessment and determine how they measure in each of the four categories. The report also provides recommendations for improvement, if needed.

“The benefits of optimizing safety through the SMI assessment can result in fewer injuries and fines, as well as improved plant productivity, greater efficiencies and enhanced employee morale,” said Mark Eitzman, safety market development manager, Rockwell Automation, who is presenting the SMI tool at the America’s Safest Companies Conference in Atlanta on Oct. 28-30, 2013. “Achieving best-in-class safety performance begins with assessing current practices companywide, and now customers can do this on their own.”

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Technip was awarded by Sasol a contract to supply its proprietary ethylene technology and front-end engineering design (FEED) for a world-class grassroots ethane cracker. This cracker, to be located at Sasol’s Lake Charles site in Louisiana, USA, will produce an estimated 1.5 million tons per annum of ethylene.

Technip’s operating center in Houston, Texas, will execute the FEED project, which is scheduled for completion by the end of 2013. Stan Knez, Technip’s Senior Vice President, Process Technology, commented: “We are pleased that Sasol selected our technology for this world-scale cracker, which will benefit from the current low US natural gas prices and abundance of ethane. As the largest ethylene licensor and contractor, Technip is proud to support Sasol’s objectives to expand its downstream business in the US.”

Yokogawa Electric Corporation announces that in December it will begin providing sensor manufacturers a new wireless communications module with a built-in antenna. This new module is intended for use in wireless sensors, and will be provided to companies that develop and manufacture these products. Yokogawa has already concluded a contract to license the use of this wireless technology to New Cosmos Electric Co., Ltd., a gas detector manufacturer.

It is expected that this module will drastically reduce the amount of time required to develop ISA100.11a*1 compliant wireless sensors.Yokogawa advocates the Wireless Anywhere concept for the plant-wide use of wireless communications technology and is working hard to promote the use of ISA100 Wireless™*2 communications technology solutions. As part of this strategy, we have developed this module.

In plants, various sensors are used to measure temperature, pressure, level, gas concentration, vibration, and so on. To develop wireless sensors for such applications, not only do manufacturers need to acquire the necessary wireless technologies, they must also comply with the radio regulations and explosion protection standards in each country. Based on the various technologies and knowledge that it has acquired through the development of field wireless systems, Yokogawa has developed a wireless communications module with a built-in antenna that can help sensor manufacturers significantly shorten the time needed for developing wireless sensor products.

New Cosmos Electric, a company with a solid track record in providing gas detection solutions to the manufacturing industry, is planning to develop a wireless gas detector. In view of its high reliability, flexible applicability, and network expandability, the company has decided on an ISA100 Wireless solution for this field wireless product. Accordingly, Yokogawa will provide this module and the technology assistance needed to develop a wireless gas detector.

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Technip was awarded by Qatar Petroleum an engineering, procurement, installation and commissioning contract for a strategically important* Offshore Project comprising a living quarter platform and an utility platform, with a bridge connecting the two platforms. The project location is within QP offshore facilities.

Technip will be responsible for the execution of the entire Project. The topsides for both platforms will be installed using the floatover technology, which Technip pioneered. This installation method enables large integrated topsides to be installed, thereby minimizing offshore hook-up and commissioning, without the use of large crane vessels.

Technip’s operating center in Abu Dhabi, United Arab Emirates, with the support from the Group’s operating centers in Paris, France and Doha, Qatar will execute the project.

Vaseem Khan, Senior Vice President of Technip in the Middle East, declared: “This contract reflects the growing interest for the floatover technology, by allowing a safe project execution in a time and cost-effective way while overcoming heavy-lift challenges. With this strategic project, we have the opportunity to further consolidate our presence in Qatar and to strengthen our relationship with Qatar Petroleum. It will also help us establish Technip as a leading Company in the region for executing offshore living quarter platform projects.”

Case Study by Yokogawa:  Total S. A. (Total) is a major oil and gas company with operations in more than 130 countries that span all aspects of the industry, including both upstream (exploration, development. and production) and downstream (refining, marketing, and the trading and shipping of petroleum products) operations. Total has been operating in Nigeria for 50 years and its deep-offshore oil & gas field development projects have been one of the main growth drivers in Africa. In Nigeria, the company operates through Total E&P Nigeria Limited (TEPNG) which carries out all upstream activities, including deep-offshore operations.

The Usan field is situated offshore Nigeria within oil mining lease (OML) 138, some 100 km south of Bonny Island, at a water depth of 750 m. Construction of the Usan FPSO by Hyundai Heavy Industries commenced in 2008 and was overseen by TEPNG. The vessel was launched in April 2011 and arrived at the field in July 2011. The Usan field came onstream in February 2012 and is able to yield 180,000 barrels of oil per day.

Usan FPSO specifications:

• Hull dimensions: 320 m long x 61 m wide x 32 m high

• Oil storage: 2 million barrels

• Oil processing: 180,000 barrels/day

• Oil-water separation: wash-tank inside the hull

• Seawater injection: 190,000 barrels/day

• Produced water treatment: 100,000 barrels/day

• Gas compression: 5.2 million standard cubic meters/day

• Topside dry gross weight: 25,000 tons

• Hull dry gross weight: 87,000 tons

• Living quarters: 130 people during normal operations (180 max.)

As the supplier of the integrated control and safety system (ICSS) for the Usan FPSO, Yokogawa Korea was involved from the early stages of this project. The delivered solutions include the CENTUM CS 3000 process control system (PCS) for the hull / topside control, the subsea control with the interface solution and overall control of wells and risers (OCWR), and the Plant Resource Manager (PRM) package for instrument management. These are integrated with third-party systems and software such as a process safety system, emergency shutdown system, fire and gas system, machine monitoring system, process data server, and operator training and maintenance system. Yokogawa’s vortex flowmeters were also installed in the field. From the very start of operations at this field, the entire facility has run safely and smoothly.

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The Siemens Industry Automation division has developed a new controller for extreme environmental conditions. Siplus S7-1500 has the same performance characteristics as the newest standard controller family Simatic S7-1500 for mid-level and high-end machine and plant automation. Other outstanding features of the new controller Siplus S7-1500 are reliable operation under extreme medial loads such as humidity, corrosive vapors, salts or dusts.In an extended temperature range, the Siplus S7-1500 functions reliably during cold starts as well as in continual operation. This saves energy costs for the user because no additional air conditioning is necessary.

Robust, enhanced modules make it possible to safely use the system everywhere from offshore plants and harsh industrial environments up to applications at extreme altitudes. The new device is protected against condensation and corrosive gasses, as well as aggressive and saline atmospheres. The Siplus S7-1500 controller has the same performance and efficiency characteristics as the Simatic S7-1500, the new standard controller generation from Siemens. Its characteristic features include outstanding system performance and a host of functions integrated as standard, including Motion Control, Security for maximum possible plant security, and Safety for safety applications that are easy to implement. Greater efficiency is represented in particular by the innovative design for simple commissioning and safe operation, the configurable diagnostic functions for the plant status and the integration into the TIA Portal for simple engineering and low project costs.

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