May 2020

Trends and Resources

Innovations

BASF has commercially launched Fourtune, a new fluid catalytic cracking (FCC) catalyst product for gasoil feedstock.

Mike Rhodes, Hydrocarbon Processing

FCC catalyst to deliver more butylene for refiners

BASF has commercially launched Fourtune, a new fluid catalytic cracking (FCC) catalyst product for gasoil feedstock. Fourtune is the latest product based on BASF’s Multiple Framework Topology (MFT) technology and has been optimized to deliver superior butylene over propylene selectivity while maintaining catalyst activity and performance.

Fourtune commercial trials have confirmed its ability to deliver better economic performance through butylene selectivity, high conversion, and maintenance of coke selective bottoms upgrading and high distillate yields that increase refiners’ profitability.

BASF’s innovative MFT technology enhances performance through the use of more than one framework topology that work together to tailor the catalyst selectivity profile. Successful evaluations of the new MFT technology have demonstrated Fourtune’s ability to help maximize margins and provide operating flexibility to make more butylene to feed the alkylation unit. The technology provides an answer to the increased demand for octane since today’s tighter sulfur regulations often require post treatment on the gasoline stream, which can negatively impact the octane pool.

IIoT ecosystem

Endress+Hauser launches its IIoT solution platform, Netilion, an ecosystem combining digital services and system components to improve the lifecycle and asset management, maintenance and support of instruments and analyzers.

Netilion enables users to keep track of their installed base, documentation and data management, and instruments’ performance and health status. Netilion’s digital services available today are Scanner, Analytics, Health, Library and Value.

Netilion Scanner is a free smartphone app that guides the user in capturing field instrument asset data, while utilizing QR code or RFID tag. It can store images and instrument location and accessibility. Critical and quality-relevant information associated with the instrument tag can also be saved.

Netilion system components, such as field gates and edge devices, can be used to upload installed base information and create lists of the instruments without having to interact with the control system. The installed base information in the digital service Netilion Analytics can be used to create a digital twin of the system and, analyzed with the help of dashboards, to initiate proactive maintenance measures for critical instruments or swap out discontinued instruments.

Netilion Health visualizes the diagnostic data provided by an instrument and receives instructions to address the issue. This improves the ability to respond in cases where maintenance or service are required. Netilion Health can track the condition of the instrument so that other maintenance optimization measures can be initiated.

Netilion Library helps users organize working files and documents. It is a file-sharing and data management service for the complete lifecycle of an instrument. Files can be continuously added to the digital twin in a traceable manner so that they are available at any time and from anywhere. This industrial file management service safely stores documents and makes them available to any device capable of hosting a web browser. This saves significant time when carrying out maintenance or engineering activities since the often-tedious search for information is eliminated.

Netilion Value is a digital service that collects process data from the field and makes them accessible anytime and anywhere. It displays the values in various features such as the dashboard, history, tracking map, and more. This makes Netilion Value a very straightforward monitoring service.

These digital services can be used separately or in concert to improve the management, maintenance and support of instrumentation systems, regardless of instrument or analyzer type or vendor.

North America flowmeters with Ethernet capability

Yokogawa Corp. of America has released its EtherNet/IP capability for the ADMAG Total Insight (TI) magnetic flowmeter. EtherNet/IP (Industrial Protocol) is an industrial network protocol that enables improved control, configuration and collection of data between field instruments and control systems across the process industries. The new capability of the ADMAG Total Insight Ethernet model offers more flexible instrumentation through a higher-level communication capability. Industries where this development is directly applicable include oil and gas, chemical, energy and power, food and beverage, and pharmaceutical.

Collection of necessary plant process data measurements with sufficient scope, accuracy and reliability is important for delivering safe, reliable and profitable operations across the process industries through effective plant control and optimization. EtherNet/IP is quickly becoming a well-known and used technology, connecting devices such as programmable logic controllers (PLC) and local and distributed I/O, while also linking many pieces of hardware on the plant floor and in industrial facilities. The bi-directional digital communication capability of EtherNet/IP makes it possible for the field instruments and control devices to perform as a complete online system, superseding the existing analog and/or fieldbus transmission lines. It facilitates transmission of large amounts of data at speeds of 10 Mbps or 100 Mbps, and up to 1,500 bytes per packet.

Migration of process control instrumentation communication to industrial Ethernet is well underway in many industries. It is expected that this migration will expand to chemical plants, refineries and upstream oil and gas as field instruments as new, intrinsically safe advanced physical layer standards become commercially available starting in 2021.

To support Yokogawa’s market expansion in North America, the ADMAG TI AXG with full-featured, mature EtherNet/IP functionality will include an embedded switch for device-level ring topology support and quick and easy integration with Rockwell Automation PLCs with advanced add-on profiles and add-on instructions.

Dual-channel gas detection controller

FIG. 1. Bacharach MGS-402 dual-channel gas detection controller.

Bacharach has introduced its MGS-402 gas detection controller (FIG. 1) for refrigerant, toxic and combustible gas detection applications. The system is designed for safety compliance in mechanical rooms, cold storage facilities, walk-in freezers, and cold room applications to –40°F/C.

The MGS-402 is part of the MGS-400 series gas detectors that connect through Modbus to up to two remote MGS-410 gas detectors at up to 1,000 ft (305 m). The MGS-402 is powered by 110-240V AC and provides three 10A output relays (fault, low-alarm, high-alarm) to initiate auxiliary ventilation or restrict refrigerant flow, two analog outputs for interface to a BMS or fire/safety panel packaged in an IP66 enclosure. Upstream Modbus connectivity enables remote configuration and communication with building management systems.

The MGS-402 has a built-in audible alarm and high-visibility visual alarm that eliminates the need for an external horn/strobe in close proximity. The remote silence input enables silencing the alarm from outside the monitored environment. Configuration of the MGS-402 is simple and intuitive, reducing installation time.

Maintenance management software

SMGlobal has released FastMaint CMMS software v.11, a computerized maintenance management software program for equipment and facilities maintenance. Maintenance managers can use FastMaint to schedule and manage preventive maintenance, as well as corrective maintenance work. They can send work orders to the maintenance staff and receive their feedback. Managers can track the progress of all outstanding and completed jobs and use FastMaint for onsite maintenance programs or field service management.

New features in version 11 include a web API to retrieve and update information via third-party apps, more work order scheduling options and user interface improvements. Since many organizations are struggling in the current situation, the previously retired Basic edition has been brought back for sites with fewer assets to manage. It has a price to suit smaller budgets.

The CMMS software is available in five editions, allowing customers to upgrade the software as their companies grow in size and complexity. The Basic and Standard editions are suited for a single user managing the maintenance process. The Standard edition adds purchase management and can handle more assets than the Basic edition.

The Professional and Web editions allow multiple users to use the system at the same time. The Cloud edition is the Web edition hosted by SMGlobal. Unlike the other editions, it does not require installation in the customer’s site.

The Basic, Standard and Professional editions require Microsoft Windows 7 or later. The Web edition needs Microsoft Windows 2008 or later for the server. The Web and Cloud editions allow client access using a desktop, laptop, Netbook, tablet or smart Phone with an HTML 5 compliant browser such as Microsoft Edge, Google Chrome, Mozilla FireFox or Apple Safari.

Analog, pulse or Modbus interface for flowmeters

FIG. 2. AW-Lake Company’s EDGE flow sensor with Bluetooth.

AW-Lake Company introduces the new EDGE Flow Sensor with optional Bluetooth for use in flowmeter applications requiring an analog, pulse or Modbus signal to a PLC or other control system. Easily mounted on meters, including AW-Lake gear meters and turbine flowmeters, the EDGE Flow Sensor (FIG. 2) outputs a frequency, current or analog signal that gives users more installation flexibility, especially when unsure of readout equipment or a control room interface.

With the ability to force the sensor to output a frequency or analog signal, connections to a user interface are verifiable without the need to run fluid flow. The sensor offers three optional pulse output configurations, including push/pull, sinking and sourcing. A Modbus output adds additional system compatibility for more advanced operations.

A Bluetooth mobile application gives users the ability to monitor and program flowmeters from the convenience of a smartphone without having to be directly in front of the unit. Operators can remotely configure, set parameters, fine-tune adjustments and troubleshoot the sensor remotely using a mobile device. The mobile application also supports basic scaling and advanced functions, allowing for remote correction of non-linear flowmeters to keep a linear analog output. Using the mobile application, users can turn a smartphone or tablet into a wireless flow monitor.

Designed with a significantly reduced package size, the EDGE Flow Sensor fits in small spaces and can connect to a PC via standard USB-C cable. More resistant to system vibration than competitive units, the sensor has no contact between the pickup nose and meter to minimize the chance of its damage due to rough handling or installation.

Software monitors corrosion of HF acid alkylation units

Emerson’s new DataManager software v8.2 helps refiners monitor corrosion of hydrofluoric (HF) acid alkylation units to prevent costly, unplanned shutdowns and maximize profits and productivity. DataManager Analysis Software for Rosemount Wireless Permasense corrosion and erosion monitoring systems offers continuous sensor monitoring that provides early detection of corrosion in HF acid alkylation units and mitigates the risk of loss of containment.

Alkylation units ensure that facilities meet gasoline quality specifications and allow for the production of premium gasoline grades, adding significant economic value to the refinery operation. These units are extremely susceptible to aggressive corrosion, which can lead to an HF release that may cause significant production loss and place the health and safety of the refinery staff and local community at risk.

Measuring corrosion damage in HF acid alkylation units using traditional methods is difficult. Iron fluoride can scale and build up on the inside of pipes, confusing normal ultrasonic thickness measurements. Additionally, traditional intrusive probes or frequent manual inspections present safety risks due to the hazardous environment of these units.

Emerson’s new version of DataManager solves these problems by helping refiners gain a better understanding of the correlation between corrosion rates and upsets or changes in process conditions.

Engineered with a unique new signal processing module, the solution delivers data directly to the engineer’s desk with wireless, non-intrusive sensors that communicate with an Emerson Wireless Gateway, reducing the frequency of manual inspections. These sensors are designed to withstand harsh, potentially high-temperature refinery conditions.

Smart universal marshalling solution

FIG. 3. The Eaton MTL SUM5 smart universal marshalling solution.

Power management company Eaton has launched its MTL SUM5 smart universal marshalling solution (FIG. 3) for process applications capable of reducing distributed control system (DCS) marshalling cabinet requirements by up to 50%. With six patents pending, MTL SUM5 combines five functions in one modular design, enabling one standard cabinet to deliver the lowest lifetime costs and lowest installed cost while saving valuable space in a control room.

Process applications requiring intrinsic safety (IS) isolation, signal conditioning, relay interfaces, surge protection and loop disconnect would typically require four different cabinet designs, with complex wiring between the marshalling components. Now, process and plant managers can benefit from a single cabinet design, with “plug and play” configurable modules for the five key marshalling functions. This eliminates the need for intricate wiring to interconnect the components, ultimately improving uptime and reducing the cost of wiring, installation and maintenance.

Since MTL SUM5 removes the need for this wiring, it also eliminates this risk of failure, therefore providing a more robust and reliable solution for processing plants in the oil and gas, petrochemical, chemical, power, pharmaceutical, and water and wastewater industries.

MTL SUM5’s modular design simplifies marshalling and provides increased flexibility throughout the product lifetime. Loop disconnect is integrated in every terminal, so loops can be easily isolated. With the modular design, this simplifies maintenance and minimizes associated costs.

There are two options of field terminal assemblies (FTAs): intrinsically safe (IS) FTAs for IS installations and general-purpose FTAs for signal conditioning or pass-through installations, which can easily be switched as the application requires. The configurable design of MTL SUM5 accommodates late changes, reducing risk during project execution as modules can easily be reconfigured or added as necessary, at any point during the build.

MTL SUM5 reduces the number of marshalling components by 65% compared to a standard solution. One MTL SUM5 universal ADIO isolator module supports the functionality provided by 20 different MTL4500 single-channel modules, while the configurable parameters enable support for an even wider range of applications. The marshalling solution provides comprehensive diagnostics, notifying the process managers when action is required. It also features LED indicators for power, function and status, which simplifies commissioning and troubleshooting. The MTL SUM5 modules are designed for both cabinet mounting in the control room, or field mounting. They are designed for ambient operating temperatures from –40°C–70°C and for mounting in a Zone 2 hazardous area, thus providing reliable operation in remote locations.

The marshalling components have a width of 10 mm that, together with the options of mounting two or three columns in each side of a standard 800-mm cabinet, delivers the highest packing density of 512 or 768 I/O channels per cabinet. This reduces the number of cabinets required, which delivers savings on cabinet hardware, installation and weight. Furthermore, a footprint of 3 m2 of control room space per cabinet is eliminated.

Standardizing on one cabinet simplifies procurement, inventory management and documentation significantly. With fewer cabinets to install, process managers can reduce costs associated with installation, commissioning, startup and maintenance further.

MTL SUM5 is designed for ATEX, IECEx and North American certification requirements to ensure safety of the plant and employees. HP

The Author

Related Articles

From the Archive

Comments

Comments

{{ error }}
{{ comment.comment.Name }} • {{ comment.timeAgo }}
{{ comment.comment.Text }}