Safety Instrumented Systems Blog

Non-Intrusive Measurements: Closing Critical Gaps Without Shutdowns

Jim Cahill — Mon, 27 Apr 2026 15:58:36 GMT

The challenge for many refiners is whether the installation risk, outage dependency, and ongoing maintenance burden can be justified. When those barriers remain in place, uncertainty forces conservative decisions. Non-intrusive measurement directly targets those constraints by allowing new measurement points to be added without cutting into piping, breaking containment, or waiting for outages.

The post Non-Intrusive Measurements: Closing Critical Gaps Without Shutdowns appeared first on the Emerson Automation Experts blog.

Boiler Safety Valves in Steam Applications

Jim Cahill — Fri, 06 Mar 2026 20:44:07 GMT

This 5:18 YouTube video, Crosby HCI Boiler Safety Valve, shows a 3D animation for the Crosby HCI Boiler Safety Relief Valve, a Section I and Section VIII ASME-rated pressure relief valve.

The post Boiler Safety Valves in Steam Applications appeared first on the Emerson Automation Experts blog.

Building Robust Process Safety on a Solid Foundation

Jim Cahill — Fri, 27 Feb 2026 19:00:39 GMT

By combining AgileOps with the real-time, dynamic simulation platform, DeltaV Mimic enables continuous operator competency management, thereby directly improving the effectiveness of operators as IPLs.

The post Building Robust Process Safety on a Solid Foundation appeared first on the Emerson Automation Experts blog.

Streamlining Overfill Proof-Testing

Jim Cahill — Mon, 12 Jan 2026 15:00:53 GMT

This two-and-a-half-minute YouTube video, Save Costs and Simplify Proof Testing with the Rosemount™ 2140 Level Detector, describes how the Rosemount 2140 level detector's vibrating fork, with smart diagnostics and fully integrated remote proof-testing, streamlines the process.

The post Streamlining Overfill Proof-Testing appeared first on the Emerson Automation Experts blog.

Role of Digital Valve Controllers in Modern Process Safety

Jim Cahill — Mon, 21 Apr 2025 13:00:53 GMT

Valves used in process safety applications remain static for much of their existence in a manufacturing or production process. Digital valve controllers can play an essential role in ensuring these valves operate as they should when called upon in an abnormal situation.

For safety valves used in throttling applications, digital valve controllers enable precise control through accurate valve positioning to avoid process instability, which can lead to unplanned shutdowns.

For open-close safety valves, digital valve controllers such as the Fisher FIELDVUE DVC6200 SIS digital valve controller can perform self-diagnostics to provide valve performance and health evaluation without shutting down the process. These diagnostics include partial stroke testing to perform slight movement on a valve to ensure it is not stuck and can perform on demand.

Other diagnostics include checking for stuck solenoids, low air supply or pressure droop, dirty air supply, and many other mechanical issues.

Fisher ValveLink software allows your maintenance and operations personnel to monitor control valve health and performance online to improve reliability by spotting problems before they affect your process. This software is used to configure, calibrate, and diagnose FIELDVUE instrumentation.

By analyzing this data over time, predictive maintenance practices can be established to flag potential failure conditions and proactively repair them to avoid unplanned incidents.

The data collected by digital valve controllers can be used for compliance support. Collected data can be used for audits to ensure adherence to safety integrity levels (SIL) and to prove that the safety valve is sufficient for the safety instrumented function in which it operates. It provides a time and date stamp on all tests and reports, which is very important for complying with the requirements of statutory authorities.

Emerson’s Riyaz Ali highlighted additional benefits in a Processing magazine article, How Digital Valve Positioners Can Simplify Safety Life Cycle Phases.

These include eliminating expensive pneumatic test panels, reducing manpower requirements, lowering base equipment cost, and shortening testing time. In addition, remote testing results in fewer maintenance trips to the field, as well as the establishment of an automated test routine.

Digital valve controllers enable manufacturers and producers to improve overall safety practices and reliability. Visit the FIELDVUE DVC6200 SIS Digital Valve Controller and Valve Reliability Suite Solutions sections on Emerson.com for solutions to help you drive operational performance improvements.

The post Role of Digital Valve Controllers in Modern Process Safety appeared first on the Emerson Automation Experts blog.

Enhancing Safety with Advanced Pressure Relief Valve Technologies

Jim Cahill — Fri, 04 Apr 2025 13:30:48 GMT

Pressure relief valves (PRVs) play a critical role in manufacturing and production processes by preventing unsafe overpressure conditions. They also affect regulatory compliance, process reliability, and the plant’s economics.

Historically, these devices, independent from the control systems, went unmonitored and required manual inspection to identify leaks and other issues. These leaks can pose safety hazards, environmental issues, and reduced production levels.

With the increasing regulatory pressure to monitor fugitive emissions from PRVs and other process equipment, the importance of monitoring has grown. Pressure relief valve monitoring solutions include sensors on the PRV and operational analytics software that transform the collected data into actionable information.

Rosemount 708 Acoustic Transmitter

PRVs come in various types, including direct spring, pilot-operated, and balanced bellows, among others. For any PRV, wireless acoustic transmitters, such as the Rosemount 708 device, can perform leak detection, identify stuck valves, and timestamp the event and duration for environmental reporting.

Fisher FIELDVUE 4400 Digital Position Transmitter

For direct spring PRVs, such as an Anderson Greenwood Series 60/80 PRV, a Fisher 4400 wired position monitor can be used to provide event timestamp and duration information as well as volumetric release amounts.

For pilot-operated PRVs, such as the Anderson Greenwood Series 200/400/500/700/800 high-pressure PRVs or Anderson Greenwood Series 90/9000 low-pressure PRVs, a Rosemount 2051 or 3051 wired or wireless differential pressure (DP) transmitter can be used to provide event timestamp and duration, and volumetric release data.

For balanced bellows PRVs, such as the Crosby J-Series PRV with a balanced diaphragm and bellows leak detection technology, the Rosemount 2051 or 3051 wired or wireless pressure transmitter provides bellows failure notification and fugitive emissions calculations.

Plantweb Insight Pressure Relief Valve software

The data from these measurement devices is sent to the Plantweb Insight Pressure Relief Valve software application, which performs machine learning-based analytics to analyze the data and provide an indication of PRV releases, including start and end times, as well as production and emissions losses.

Early detection with actionable information helps manufacturers and producers minimize unsafe conditions caused by leaking or stuck PRVs and improve regulatory reporting, ultimately enhancing overall sustainability.

The post Enhancing Safety with Advanced Pressure Relief Valve Technologies appeared first on the Emerson Automation Experts blog.

Driving Quality and Safety in Electric Vehicle Battery Production

Jim Cahill — Tue, 25 Mar 2025 13:00:26 GMT

Most of today’s electric vehicles (EVs) rely on lithium-ion (Li-ion) batteries due to their high-energy density. As these batteries have become increasingly more advanced, so has the manufacturing process required to produce them—a complex interplay of chemical production and intricate assembly.

To meet the stringent production requirements, ensuring quality, safety, and reliability is paramount in the manufacturing of various components that make up the battery cell. The inherent variability of raw materials and the need for precise application of different gels, pastes, slurries, and liquid coatings make consistency across batches essential.

In an article published in Process Instrumentation magazine, Michael Machuca shares ways producers can leverage data from advanced measurement instrumentation and automation to manufacture high-quality Li-ion battery components at scale. He also covers strategies for optimizing the battery recycling process for successful resource recovery and waste reduction. The article focuses on three main chemical components of the battery: the cathode, anode, and electrolyte.

The anode is usually a copper foil coated with graphite, which is ground to a specific size, made into a slurry, applied to the copper and baked to bond, while maintaining conductivity and porosity. The cathode, more complex and variable by manufacturer, often comprises alloys like lithium-nickel-manganese-cobalt oxide or lithium-iron-phosphate, requiring high purity to avoid contamination. It is processed into a powder and applied to a metal foil. Electrolytes mix lithium salt, mainly lithium hexafluorophosphate, in an organic solvent, with additives to stabilize ion flow and protect the anode and cathode.

Monitoring Quality at Every Production Stage

Ensuring quality in batch manufacturing relies on recipe consistency and the precise measurement of ingredients. Achieving a high level of precision and addressing the variability in material properties and process conditions requires reliable data from measurement technologies. This includes:

The Micro Motion™ ELITE™ Peak Performance Coriolis Flow and Density Meter delivers high precision and a wide turn-down ratio, making it an ideal choice for measuring liquids, slurries and gases.

Mass flow and density meters. They provide direct mass flow measurement of liquids, slurries, and gases, crucial for accurate ingredient addition which is essential given the density variations.
Monitoring and controlling pH levels using sensors is vital, especially when handling reactive materials.
Viscosity control, critical for coatings or specific flow characteristics, can be achieved with instruments such as fork viscosity meters, enabling real-time adjustments.
Conductivity measurements using toroidal conductivity sensors are critical for electrolyte quality control, directly indicating the electrolyte’s ability to facilitate ion flow.
Non-contacting radar level transmitters to verify total batch volume, ensuring adherence to production specifications.

Ensuring Safety

The manufacturing of Lithium-ion cells involves highly reactive and hazardous materials, making safety a top priority.

Facilities can utilize advanced toxic gas detectors, such as Emerson’s Rosemount 928 Wireless Gas Monitor and Rosemount 925FGD Fixed Gas Detector, for early detection of hazardous gas leaks.
Flame detectors such as the Rosemount 975 Ultra Fast Ultraviolet Infrared Flame Detector are crucial for rapid detection of radiant energy.
Enhancing process safety with the integration of safety-certified instruments compliant with IEC 61508 into safety-instrumented systems to prevent accidents, by closely monitoring pressure, temperature, flow, and level.
Emerson’s safety-certified instruments and sensors cover various safety needs for battery manufacturing environments.

Improving Reliability

Intelligent process instrumentation also plays a key role in enhancing reliability through diagnostic capabilities that allow for proactive maintenance and better decision-making. This includes:

Corrosion and erosion can be continuously monitored via wireless ultrasonic thickness sensors that detect corrosive conditions and the actual loss of metal.

Smart Meter Verification software, compatible with Emerson flow meters, provides real-time performance monitoring and historical data review.
Continuous corrosion and erosion monitoring systems, such as the Rosemount Wireless Permasense ET410, provide real-time thickness measurements to ensure equipment integrity.
Wireless devices and Bluetooth-enabled instrumentation offer flexibility by solving unique application challenges, such as mobile reactors that must be transported for cleaning after each batch. Wireless monitoring reduces the risk of damage and simplifies configuration and diagnostics, leading to cost savings.

Recycling Batteries

As EV batteries reach their end of life, recycling becomes critical for resource recovery and waste reduction. Many of the measurement instruments used in battery manufacturing, such as magnetic flow meters, pH sensors, and radar level transmitters, are also applicable to the challenges of battery recycling, including acid measurement in leaching processes and level monitoring in corrosive environments.

Read the article for more information on how data from advanced measurement and monitoring technologies are indispensable for successful EV battery manufacturing. By enabling precise quality control, ensuring robust safety measures, and improving equipment reliability, these sensors empower manufacturers to meet stringent product specifications and optimize resource utilization. Partnering with automation technology experts is crucial for organizations across the entire lithium value chain to achieve high-quality Li-ion battery production at scale.

The post Driving Quality and Safety in Electric Vehicle Battery Production appeared first on the Emerson Automation Experts blog.

When is a SIL Suitability Rating Required for Final Control Elements?

Jim Cahill — Mon, 17 Mar 2025 11:00:32 GMT

Update and bump: A LinkedIn post on this subject went viral, so I thought it would be worth sharing Riyaz Ali‘s thoughts on this subject again.

Abstract

Final Control Elements (Control valves or Safety Shut Down Valves) are the key components of any close loop control system, whether it is used for Basic Process Control Systems (BPCS) or for Safety Instrumented Systems (SIS). Financial constraints derive different constructions of valves suitable for throttling vs On-Off applications. However, due to past accidents, reliability has become a key criterion in the valve selection process. Many process industry manufacturers and producers, based on their plant-specific experiences, are tempted to use control valves in safety shutdown applications—specifically smaller-size valves, which may not be cost-prohibitive. This post will provide clarity on when to assign the SIL suitability for valves used in different scenarios (process control vs. safety shutdown) and establish criteria to assign SIL applicability for the “Final Element”.

Introduction

Safety integrity Level (SIL) is the discrete level for specifying the safety integrity requirements of the safety instrumented functions. It is a quantifiable measurement of risk used to establish safety performance targets of SIS systems. A SIL can be expressed in terms of Probability of Failure on Demand (PFD) or Risk Reduction Factor (RRF). Risk reduction factor is simply the reciprocal of PFD (1/PFD). SIL levels are designated in terms of PFD or RRF as a range of numbers.

PFD is a value that indicates the probability of a system failing to respond to a demand. PFD is a function of test interval time and failure rate of the equipment under control.

In short, to establish an SIL suitability rating for a Safety Instrumented Function (SIF) loop, a PFD value needs to be computed for the components of a loop. A SIF loop consists of a sensor, logic solver and final element. To calculate PFD, an equipment failure rate number is required.

Failure Mechanism

Failures are categorized so that failure data can be organized in a consistent way. ISA Technical report ISA-TR84.00.02-2002 – Part 1 talks about two failure modes – physical (random) failures and functional (systematic) failures.

Physical or random failures result from the degradation of one or more hardware mechanisms. It is often permanent and attributable to some component or module. For example, when a control valve is at the end of travel and not moving with the change in the control signal due to a broken shaft, the failure has occurred because of a physical failure of the component in the valve.

On the other hand, functional or systematic failures are failures related in a deterministic way to a certain cause, which can be eliminated by a modification of the design or manufacturing process, operational procedures, or other relevant factors. For example, a computer program has crashed and there is no physical damage, but the system has failed. The end result is that the program is not working, and a failure has occurred due to a systematic error in programming code.

A major distinguishing feature between a random failure and a systematic failure is that failures arising from a random failure can be predicted with reasonable accuracy, while systematic failures, by their very nature, cannot be accurately predicted.

With a basic understanding of failure mechanisms, it is clear that mechanical items like control valves, failures can be classified under the physical or random failure category, which is simpler by nature.

Systematic failures are typical characteristics of programmable electronic systems or microprocessor-based devices. The reliability concept has been around the industry for a long time but due to advancements in electronics and control systems, this concept is more crucial than ever before. Because a final control element is part of the control loop, its reliability data is also being questioned by end-users.

This leads to a basic question:

Does a “final control element” require a SIL suitability rating?

To understand the exact need, let us discuss control systems used in process sector industries. Control systems are frequently separated into two categories: systems that protect the equipment, classified as “Safety Instrumented System” and systems that control the equipment, known as “Basic Process Control System.” Final control elements are part of both systems.

According to IEC 61511 part 1, 3.2.3, Basic Process Control System has been defined as:

Basic Process Control System (BPCS)

A system which responds to input signals from the process, its associated equipment, other programmable systems and/or an operator and generates output signals causing the process and its associated equipment to operate in the desired manner but which does not perform any safety instrumented functions with a claimed SIL ≥ 1.

This definition leads us to conclude that a BPCS is any system that has a SIL<1. Therefore, SIS systems employing Safety Instrumented Functions with a specified safety integrity level, which is necessary to achieve safety function, need to have a SIL rating equal to or above 1.

This above conclusion raises some interesting questions:

1. Why are control valves to be SIL certified?

Industry practices and routines generally define which valve design need to be used for a safety versus control applications. However, due to reliability attributes of control valves, especially on smaller sizes, make them suitable for safety applications.

Financial considerations and maintenance aspects (using same valve design for both control and safety) are making control valves attractive for safety applications. We can categorize in three different scenarios as below, where control valves can be used as safety shut down valves.

CASE 1: Control valves which are used only as an on/off single final element

CASE 2: Control valves which are used in a dual-purpose context (both for control and safety)

CASE 3: Control valves which are used in a dual-purpose context in addition (redundancy) to an on/off valve

Illustration for Case 1

A control valve is used for safety applications. In this case the control valve is a “Final Element” of a SIF Loop and needs to have SIL rating equal to or above 1.

Case 1

Illustration for Case 2

Is it possible to use single control valve common for both safety and control?

According to IEC 61511 part 1 clause 11.2.10, it states that a device used to perform part of a safety instrumented function shall not be used for basic process control purposes, where a failure of that device results in a failure of the basic process control function which causes a demand on the safety instrumented function, unless an analysis has been carried out to confirm that overall risk is acceptable.

This may possibly lead to following interpretation.

YES: If all possible failures of the control valve do not place a demand on any SIF than control valve may be used with no further analysis. In this case, the control valve is the “Final Element” of SIF loop, and it needs to have a SIL rating equal to or above 1.
NO: If failure of the control valve will place a demand on a SIF, then it may not be used as the only final element in that SIF.
If failure of the control valve will not place a demand on SIF, for which it is intended but may place demand on any other associated SIF than the control valve may be used in a SIF only after detailed analysis. An additional step for further analysis will be necessary in these cases to ensure that the dangerous failure rate of the shared equipment is sufficiently low. In this case, the control valve is a “Final Element” of the SIF loop, and it needs to have SIL rating equal to or above 1.

Case 2

Illustration for Case 3

In this scenario, a control valve is used to provide additional hardware fault tolerance for a higher SIL application, which is like using a control valve for safety but with the added burden of justifying and verifying the SIF design and its final SIL value.

Case 3

2. Why are control valves that are used in a BPCS required to be SIL certified?

As per IEC definition, a SIL rating is not required but it is possible that reliability data for a valve may be required. Industry or end user may require failure rate data of equipment or in loose terms, MTBF (Mean Time Between Failure).

Essentially MTTF (mean time to fail) is the right term to define product reliability. It is usually furnished in units of hours. This is more common for electronic components, but trends are seen even for mechanical items.

3. How can MTTF provide useful data for the calculation of PFD_AVG (probability of failure upon demand)?

MTTF can be simplified to 1/(sum of all failure rates) or equal to 1/λ. In general, components of MTTF can be categorized in the following categories:

Safe Detected (λ^SD)

Safe Undetected (λ^SU)

Dangerous Detected (λ^DD)

Dangerous Undetected (λ^DU)

This data leads to useful information:

MTTFs (Mean time to Fail Safe)
MTTFd (Mean time to fail Dangerous)
SFF (Safe Failure Fraction)

MTTFs can be computed by adding λ^SD and λ^SU and reversing the number. MTTFd can be computed by taking λ^DU and reversing the number.

SFF can be computed using the equation = 1 – (λ^DU) / (λ^SD + λ^SU + λ^DD + λ^DU) or (λ^SD + λ^SU + λ^DD) / (λ^SD + λ^SU + λ^DD + λ^DU).

PFD_AVG can be calculated using simplified equation of failure rate of equipment under control (EUC) times test interval divided by two.

MTTFs calculations provide plant availability, which is a very important measurement of process plant up-time capability. A spurious trip that is considered a safe but unplanned trip may be too strenuous for piping and other equipment. Not only are production and quality affected, but profits may also be as well. Also, it is important to consider the higher risk associated with plant start up. IEC 61508 stresses more on “safety event”, in case of demands, which relates to dangerous undetected failures and are used to compute PFDavg.

As such, mechanical equipment like valve bodies and actuators do not have any diagnostics capabilities. According to IEC 61508 part 2, table 2, with a hardware fault tolerance (HFT) of zero, they can only be used in SIL 1 applications. A digital valve controller mounted on a “Final Control Element” improves the diagnostic coverage factor, which in turn improves the SFF number, allowing the possible use of higher SIL rated applications (Per IEC 61508 part 2, table 3) by use of the Partial Stroke Test.

Conclusion

If control valve is designated to carry out a safety function, then it should meet the SIL level of the Safety Instrumented System Function loop. In this case, failure rate numbers will be required to compute the total PFDavg of the loop. The end user may possibly ask for third party certification to comply with IEC 61508 requirements to meet certain SIL suitability.

However, if a control valve is designated for normal process control than as per IEC61511-3 part 1, section 3.2.3, Basic Process Control System, definition does not designate control valves to have SIL suitability.

References

i) International Electrotechnical Commission, “Functional Safety – Safety instrumented systems for the process industry sector” – IEC61511
ii) International Electrotechnical Commission, “Functional Safety of Electrical / Electronic / Programmable Electronic Safety-Related Systems” – IEC61508
iii) Control Systems Safety Evaluation & Reliability – William M Goble
iv) ISA Technical report ISA-TR84.00.02-2002 – Part 1

The post When is a SIL Suitability Rating Required for Final Control Elements? appeared first on the Emerson Automation Experts blog.

Outstanding Measurement Reliability Vital in Preventing LNG Tank Overfills

Jim Cahill — Thu, 01 Aug 2024 13:01:38 GMT

To optimize safety, it is essential to obtain accurate measurements of the liquid levels within LNG tanks.

It is essential to obtain very precise and reliable level measurements in the cryogenic or refrigerated tanks that store liquefied natural gas (LNG), as this helps to prevent overfills, optimize site and worker safety, and ensure compliance with environmental regulations. Level measurement technology forms an integral part of the overfill prevention systems (OPS) that minimize the risk of potentially disastrous spills and leaks from LNG tanks. However, as I explained in a Hazardex article, ‘How Advanced Radar Technology Increases Safety at LNG Terminals’, measuring the level of LNG is a challenging application.

LNG is a hazardous fuel, stored in large tanks with a capacity of up to 200,000 cubic meters. The required level measurement range often exceeds 40 meters (131 feet), making it difficult to achieve a high degree of accuracy. In addition, these tanks are not usually opened during operation or even for maintenance purposes during their entire lifecycle. This makes it important to select exceptionally reliable level measurement technology with minimal maintenance needs. The article explains that the modern approach to level measurement in LNG tanks is to use non-contacting radar gauges. It states:

…Radar level gauges work by emitting microwave signals towards the surface of the liquid, and a precise measurement is achieved by analysing the signals reflected back to the transmitter. A strong reflected signal, commonly referred to as an echo, is required to ensure a reliable measurement. To maximise signal strength, the latest radar gauges leverage frequency modulated continuous wave (FMCW) technology, boasting a sensitivity more than 30 times greater than devices using older pulse modulation techniques.

This heightened sensitivity enables FMCW devices, such as the Rosemount 5900S Radar Level Gauge from Emerson, to deliver superior measurement accuracy. To mitigate the fact that the device’s signal strength can be impacted by disturbances to the liquid surface, a still-pipe can be deployed to minimize such disturbances, resulting in a more robust echo.

The Rosemount 5900S Radar Level Gauge provides measurement accuracy to within an impressive 0.5 millimeters (0.020 inches) at distances in excess of 60 meters (196 feet). This level of precision facilitates a reduction in volume uncertainty of up to 180% compared to less sophisticated methods such as servo gauges. The radar device provides a further significant advantage through its ability to verify its measurements whilst a tank remains in operation. This is achieved by comparing its measured values to the known distance of a verification pin mounted in the still-pipe, along with a deflection plate at the end of the pipe.

The Rosemount 5900S Radar Level Gauge excels in measuring the levels of LNG in cryogenic or refrigerated tanks.

Despite the benefits of radar technology, some organizations have continued to use servo technology on LNG tanks because of concerns that high gas density in the vapor space might impact the performance of radar level gauges. However, as the article explains:

…these concerns are unfounded, as vapour and high gas density do not influence radar signals or compromise the measurement accuracy of radar gauges. In reality, radar gauges excel in measuring the levels of liquefied gases in cryogenic or refrigerated tanks. This is evident in their successful deployment on more than 8,000 liquefied gas tanks worldwide over almost 40 years.

In addition to their exceptional measurement accuracy, non-contacting radar gauges provide outstanding reliability. During their long lifespan, their availability is usually close to 100%, helping to ensure that the operational availability of tanks is maximized. The article continues:

…The design of non-contacting radar level gauges – devoid of moving parts and eliminating the need for contact with the liquid – minimises maintenance requirements. The mean time between failures for critical parts is measured in decades, and should a failure occur, diagnostic software will typically identify it and take the device to a safe state.

In LNG storage applications, it is common practice to install three level gauges per tank – one supporting the tank gauging system; a second, redundant gauge for inventory; and a third providing information for the OPS – with safety instrumented system (SIS) alarms triggered on a two-out-of-three voting scheme. The article explains that the International Electrotechnical Commission’s global functional safety standard IEC 61511 validates the same level measurement technology being used for both tank gauging and the OPS – an approach known as identical separation.

Whilst radar devices can easily be used for both tank gauging and OPS purposes on new LNG tanks, existing tanks may have practical limitations that make it cost-prohibitive to deploy two separate radar level gauges. The article states:

…Scenarios where only one tank opening is available, and modifications would involve taking the tank out of service, can result in additional costs and reduced throughput. Addressing this challenge, 2-in-1 radar level gauges provide an innovative solution.

The Rosemount 5900S Radar Level Gauge can serve as both an automatic tank gauge and an independent overfill prevention sensor, and requires just a single tank opening.

The Rosemount 5900S Radar Level Gauge consists of two separate and independent electrical units and a common antenna. By connecting the cables separately in different cable trays and utilizing separate power sources, a single level gauge can provide a ‘2-in-1’ option, serving as both an automatic tank gauge and an independent overfill prevention sensor. The article explains:

…The primary advantage of this 2-in-1 configuration is its efficiency in requiring only a single tank opening. This allows for cost-efficient upgrades of existing tanks by replacing a single automatic tank gauge or overfill prevention sensor with two continuous level measurements, necessitating minimal tank modifications. Often, a radar level gauge with 2-in-1 technology fits the antenna of earlier generations of devices, thereby requiring no tank modifications at all.

Visit here to learn more about Emerson’s measurement solutions for cryogenic and refrigerated tanks.

The post Outstanding Measurement Reliability Vital in Preventing LNG Tank Overfills appeared first on the Emerson Automation Experts blog.

Outstanding Measurement Reliability Vital in Preventing LNG Tank Overfills

Jim Cahill — Thu, 01 Aug 2024 13:01:38 GMT

To optimize safety, it is essential to obtain accurate measurements of the liquid levels within LNG tanks.

…Radar level gauges work by emitting microwave signals towards the surface of the liquid, and a precise measurement is achieved by analysing the signals reflected back to the transmitter. A strong reflected signal, commonly referred to as an echo, is required to ensure a reliable measurement. To maximise signal strength, the latest radar gauges leverage frequency modulated continuous wave (FMCW) technology, boasting a sensitivity more than 30 times greater than devices using older pulse modulation techniques.

The Rosemount 5900S Radar Level Gauge excels in measuring the levels of LNG in cryogenic or refrigerated tanks.

…these concerns are unfounded, as vapour and high gas density do not influence radar signals or compromise the measurement accuracy of radar gauges. In reality, radar gauges excel in measuring the levels of liquefied gases in cryogenic or refrigerated tanks. This is evident in their successful deployment on more than 8,000 liquefied gas tanks worldwide over almost 40 years.

…The design of non-contacting radar level gauges – devoid of moving parts and eliminating the need for contact with the liquid – minimises maintenance requirements. The mean time between failures for critical parts is measured in decades, and should a failure occur, diagnostic software will typically identify it and take the device to a safe state.

…Scenarios where only one tank opening is available, and modifications would involve taking the tank out of service, can result in additional costs and reduced throughput. Addressing this challenge, 2-in-1 radar level gauges provide an innovative solution.

The Rosemount 5900S Radar Level Gauge can serve as both an automatic tank gauge and an independent overfill prevention sensor, and requires just a single tank opening.

…The primary advantage of this 2-in-1 configuration is its efficiency in requiring only a single tank opening. This allows for cost-efficient upgrades of existing tanks by replacing a single automatic tank gauge or overfill prevention sensor with two continuous level measurements, necessitating minimal tank modifications. Often, a radar level gauge with 2-in-1 technology fits the antenna of earlier generations of devices, thereby requiring no tank modifications at all.

Visit here to learn more about Emerson’s measurement solutions for cryogenic and refrigerated tanks.

The post Outstanding Measurement Reliability Vital in Preventing LNG Tank Overfills appeared first on the Emerson Automation Experts blog.

Outstanding Measurement Reliability Vital in Preventing LNG Tank Overfills

Jim Cahill — Thu, 01 Aug 2024 13:01:38 GMT

To optimize safety, it is essential to obtain accurate measurements of the liquid levels within LNG tanks.

…Radar level gauges work by emitting microwave signals towards the surface of the liquid, and a precise measurement is achieved by analysing the signals reflected back to the transmitter. A strong reflected signal, commonly referred to as an echo, is required to ensure a reliable measurement. To maximise signal strength, the latest radar gauges leverage frequency modulated continuous wave (FMCW) technology, boasting a sensitivity more than 30 times greater than devices using older pulse modulation techniques.

The Rosemount 5900S Radar Level Gauge excels in measuring the levels of LNG in cryogenic or refrigerated tanks.

…these concerns are unfounded, as vapour and high gas density do not influence radar signals or compromise the measurement accuracy of radar gauges. In reality, radar gauges excel in measuring the levels of liquefied gases in cryogenic or refrigerated tanks. This is evident in their successful deployment on more than 8,000 liquefied gas tanks worldwide over almost 40 years.

…The design of non-contacting radar level gauges – devoid of moving parts and eliminating the need for contact with the liquid – minimises maintenance requirements. The mean time between failures for critical parts is measured in decades, and should a failure occur, diagnostic software will typically identify it and take the device to a safe state.

…Scenarios where only one tank opening is available, and modifications would involve taking the tank out of service, can result in additional costs and reduced throughput. Addressing this challenge, 2-in-1 radar level gauges provide an innovative solution.

The Rosemount 5900S Radar Level Gauge can serve as both an automatic tank gauge and an independent overfill prevention sensor, and requires just a single tank opening.

…The primary advantage of this 2-in-1 configuration is its efficiency in requiring only a single tank opening. This allows for cost-efficient upgrades of existing tanks by replacing a single automatic tank gauge or overfill prevention sensor with two continuous level measurements, necessitating minimal tank modifications. Often, a radar level gauge with 2-in-1 technology fits the antenna of earlier generations of devices, thereby requiring no tank modifications at all.

Visit here to learn more about Emerson’s measurement solutions for cryogenic and refrigerated tanks.

The post Outstanding Measurement Reliability Vital in Preventing LNG Tank Overfills appeared first on the Emerson Automation Experts blog.

Avoiding Unplanned Downtime with Smart Pneumatic and Hydraulic Valve Monitoring

Jim Cahill — Thu, 30 May 2024 11:00:08 GMT

A Forbes article, Unplanned Downtime Costs More Than You Think, cites this statistic:

An overwhelming 82% of companies have experienced at least one unplanned downtime incident over the past three years. Most have suffered two or more.

In an Industrialvalves.de article, Outperforming traditional Valve design meets smart monitoring system for pneumatic and hydraulic valve actuators, Emerson’s Knut Riegel shares ways to avoid unplanned downtime caused by valves equipped with fluid-powered actuators.

Knut opens the article by highlighting the use of these valves in safety instrumented system (SIS) applications. He describes the concept of a safety integrity level (SIL) and how this analysis is done in accordance with the IEC 61511 and IEC 61508 global safety standards.

Electric valve actuators can be effectively used in SIS applications.

Electric valve actuators offer many advantages—such as enabling preventive maintenance, partial stroke tests, timestamped event logs, and communications via standard protocols— and have been successfully implemented in a range of applications and industries. Thus, many greenfield projects are equipped directly with electrics, such as Emerson’s Bettis XTE3000, rather than conventional air-powered actuators with a control unit.

Knut explains how electric valve actuators are incorporated.

Pneumatic low-pressure actuators and especially hydraulic high-pressure solutions are often used as emergency shutdown (ESD) devices designed to stop the flow of a hazardous fluid upon detecting a dangerous event. These devices are usually used to control the functions of a control unit using additional smart valve positioners and analog limit switch boxes, with a smart electric valve actuator added to gain benefits from it.

Testing the performance of valves used in safety instrumented functions must be done periodically.

ESD [emergency shutdown] functionality is usually only tested during planned maintenance events (STOs) by a full stroking test (FST), in which the valve is completely opened or closed. This is because the system cannot be tested during operation, as it would disrupt the process and prevent the maximum production capacity from being reached. The ESD mode typically switches the solenoid valve off from the power source, and the valve moves into its emergency position. However, this would mean a disruption of the process.

Biffi IMVS2

Testing intervals to perform full stroke tests can be extended by performing partial stroke testing (PST). Knut described Emerson’s Smart Integrated Monitoring of Valve Systems (IMVS), the Biffi IMVS2, for fluid-powered (pneumatic and hydraulic) valve actuators as:

…an intelligent partial lifting device particularly suitable for preventive diagnostics in valve solutions that use compressed air or mineral oil as a working medium.

He details how the IMVS works.

The sensor-integrated, electromechanical IMVS is operated on single (spring close/open) or double-acting pneumatics, as well as hydraulic actuators, mounted analogously to a limit switch box, and controlled by a separate single or redundant solenoid valve. Diagnostics, operational insights, and safety functions are thus guaranteed. The SOVs (solenoid valves) used are explicitly tested for each partial stroke test, as they are switched voltage-free at the same time at the start of the test. Still, it is also possible to test the functionality of each SOV separately without a partial stroke test.

During the partial or full stroke test, the integrated IMVS controls the SOV, which is used to control the actuator as a combination of valve and actuator. This ensures that the actual dynamics of the automated valve package are detected, and that the solenoid valve is fundamentally checked in parallel. The partial stroke describes a movement at an angle of 10 to 15 degrees (with a 90°-fitting) to avoid possible effects on the process. The Partial Stroke Test (PST) angle is settable in the intuitive device menu.

Read the article for more on how this IMVS solution is fitted onto premium process valves, such as a Vanessa Series 30,000 triple-offset valve, to help you avoid unplanned downtime through predictive analysis.

The post Avoiding Unplanned Downtime with Smart Pneumatic and Hydraulic Valve Monitoring appeared first on the Emerson Automation Experts blog.

Avoiding Unplanned Downtime with Smart Pneumatic and Hydraulic Valve Monitoring

Jim Cahill — Thu, 30 May 2024 11:00:08 GMT

A Forbes article, Unplanned Downtime Costs More Than You Think, cites this statistic:

An overwhelming 82% of companies have experienced at least one unplanned downtime incident over the past three years. Most have suffered two or more.

Electric valve actuators can be effectively used in SIS applications.

Electric valve actuators offer many advantages—such as enabling preventive maintenance, partial stroke tests, timestamped event logs, and communications via standard protocols— and have been successfully implemented in a range of applications and industries. Thus, many greenfield projects are equipped directly with electrics, such as Emerson’s Bettis XTE3000, rather than conventional air-powered actuators with a control unit.

Knut explains how electric valve actuators are incorporated.

Pneumatic low-pressure actuators and especially hydraulic high-pressure solutions are often used as emergency shutdown (ESD) devices designed to stop the flow of a hazardous fluid upon detecting a dangerous event. These devices are usually used to control the functions of a control unit using additional smart valve positioners and analog limit switch boxes, with a smart electric valve actuator added to gain benefits from it.

Testing the performance of valves used in safety instrumented functions must be done periodically.

ESD [emergency shutdown] functionality is usually only tested during planned maintenance events (STOs) by a full stroking test (FST), in which the valve is completely opened or closed. This is because the system cannot be tested during operation, as it would disrupt the process and prevent the maximum production capacity from being reached. The ESD mode typically switches the solenoid valve off from the power source, and the valve moves into its emergency position. However, this would mean a disruption of the process.

Biffi IMVS2

…an intelligent partial lifting device particularly suitable for preventive diagnostics in valve solutions that use compressed air or mineral oil as a working medium.

He details how the IMVS works.

The sensor-integrated, electromechanical IMVS is operated on single (spring close/open) or double-acting pneumatics, as well as hydraulic actuators, mounted analogously to a limit switch box, and controlled by a separate single or redundant solenoid valve. Diagnostics, operational insights, and safety functions are thus guaranteed. The SOVs (solenoid valves) used are explicitly tested for each partial stroke test, as they are switched voltage-free at the same time at the start of the test. Still, it is also possible to test the functionality of each SOV separately without a partial stroke test.

During the partial or full stroke test, the integrated IMVS controls the SOV, which is used to control the actuator as a combination of valve and actuator. This ensures that the actual dynamics of the automated valve package are detected, and that the solenoid valve is fundamentally checked in parallel. The partial stroke describes a movement at an angle of 10 to 15 degrees (with a 90°-fitting) to avoid possible effects on the process. The Partial Stroke Test (PST) angle is settable in the intuitive device menu.

The post Avoiding Unplanned Downtime with Smart Pneumatic and Hydraulic Valve Monitoring appeared first on the Emerson Automation Experts blog.

Avoiding Unplanned Downtime with Smart Pneumatic and Hydraulic Valve Monitoring

Jim Cahill — Wed, 29 May 2024 11:00:08 GMT

A Forbes article, Unplanned Downtime Costs More Than You Think, cites this statistic:

An overwhelming 82% of companies have experienced at least one unplanned downtime incident over the past three years. Most have suffered two or more.

Electric valve actuators can be effectively used in SIS applications.

Electric valve actuators offer many advantages—such as enabling preventive maintenance, partial stroke tests, timestamped event logs, and communications via standard protocols— and have been successfully implemented in a range of applications and industries. Thus, many greenfield projects are equipped directly with electrics, such as Emerson’s Bettis XTE3000, rather than conventional air-powered actuators with a control unit.

Knut explains how electric valve actuators are incorporated.

Pneumatic low-pressure actuators and especially hydraulic high-pressure solutions are often used as emergency shutdown (ESD) devices designed to stop the flow of a hazardous fluid upon detecting a dangerous event. These devices are usually used to control the functions of a control unit using additional smart valve positioners and analog limit switch boxes, with a smart electric valve actuator added to gain benefits from it.

Testing the performance of valves used in safety instrumented functions must be done periodically.

ESD [emergency shutdown] functionality is usually only tested during planned maintenance events (STOs) by a full stroking test (FST), in which the valve is completely opened or closed. This is because the system cannot be tested during operation, as it would disrupt the process and prevent the maximum production capacity from being reached. The ESD mode typically switches the solenoid valve off from the power source, and the valve moves into its emergency position. However, this would mean a disruption of the process.

Biffi IMVS2

…an intelligent partial lifting device particularly suitable for preventive diagnostics in valve solutions that use compressed air or mineral oil as a working medium.

He details how the IMVS works.

The sensor-integrated, electromechanical IMVS is operated on single (spring close/open) or double-acting pneumatics, as well as hydraulic actuators, mounted analogously to a limit switch box, and controlled by a separate single or redundant solenoid valve. Diagnostics, operational insights, and safety functions are thus guaranteed. The SOVs (solenoid valves) used are explicitly tested for each partial stroke test, as they are switched voltage-free at the same time at the start of the test. Still, it is also possible to test the functionality of each SOV separately without a partial stroke test.

During the partial or full stroke test, the integrated IMVS controls the SOV, which is used to control the actuator as a combination of valve and actuator. This ensures that the actual dynamics of the automated valve package are detected, and that the solenoid valve is fundamentally checked in parallel. The partial stroke describes a movement at an angle of 10 to 15 degrees (with a 90°-fitting) to avoid possible effects on the process. The Partial Stroke Test (PST) angle is settable in the intuitive device menu.

The post Avoiding Unplanned Downtime with Smart Pneumatic and Hydraulic Valve Monitoring appeared first on the Emerson Automation Experts blog.

Meeting Safety Challenges in Hydrogen Applications

Jim Cahill — Mon, 29 Apr 2024 05:00:04 GMT

Pressure safety valves (PSVs) play a vital role in ensuring the safe operation of industrial processes and equipment by preventing overpressure situations that could lead to serious accidents causing injuries or even fatalities, as well as significant environmental damage. PSVs are particularly crucial in high-pressure hydrogen systems due to the safety challenges associated with hydrogen gas. These challenges include the highly flammable nature of hydrogen gas, and the fact that it can cause embrittlement in certain materials, potentially compromising the integrity of system components over time.

In a presentation at the Emerson Exchange EMEA 2024 in Düsseldorf, Luis Sancho, reliability manager at the ILBOC refinery in Cartagena, Spain, stressed the importance of investing in the best possible safety devices for hydrogen applications. This includes not only PSVs but also ultrasonic detectors to monitor equipment and trigger an early warning system in the event of a gas leak.

Sancho explained that in hydrogen applications, the use of modulating action pilot operated (MAPO) PSVs delivers several benefits. They provide precise control over the relief pressure by modulating the valve’s opening in response to changes in system pressure. This allows for more accurate pressure regulation, ensuring that hydrogen systems operate within safe limits without experiencing unnecessary pressure fluctuations. MAPO valves can also mitigate pressure spikes more effectively than conventional relief valves by gradually opening and closing in response to pressure variations. This helps to minimize the risk of sudden pressure surges that could lead to equipment damage or safety hazards. In addition, robust MAPO valves are designed for high reliability and durability, making them well suited to demanding hydrogen service conditions.

Sancho then told delegates that there are several benefits to using a soft seated PSV rather than a metal seated valve in hydrogen applications. Crucially, soft seated valves provide enhanced sealing performance and tight shut-off, thereby minimizing the risk of hydrogen leaks. Soft seated valves also typically require less maintenance than metal seated valves, resulting in a longer service life and reduced downtime for maintenance activities. Furthermore, soft seats materials are compatible with hydrogen gas, which minimizes the risk of material degradation or embrittlement over time.

Although the risk of hydrogen gas leaks can be minimized, it is inevitable that they will still occasionally occur. Sancho said that when this happens, it is crucial to detect the leak as quickly as possible. He described how two Emerson devices – the Rosemount™ 708 Wireless Acoustic Transmitter and the Rosemount Incus Ultrasound Gas Leak Detector – are providing reliable gas leak detection at the ILBOC refinery in Cartagena.

When pressurized hydrogen gas leaks from a valve, it produces high-frequency acoustic waves or noise. The Rosemount 708 Wireless Acoustic Transmitter is equipped with an acoustic sensor that can detect this noise. The transmitter processes the acoustic signals it receives from the sensor using advanced algorithms, to distinguish the signals from background noise and identify them as potential gas leaks. The transmitter then wirelessly transmits an alarm signal to a central control system or monitoring station, enabling appropriate response actions to be triggered. The continuous, real-time monitoring provided by the device helps to prevent the potential safety hazards, environmental impacts, and equipment damage associated with uncontrolled hydrogen gas leaks. Sancho explained that a single Rosemount 708 Wireless Acoustic Transmitter enables ILBOC to monitor several PSVs at the same time, even when they are separated by tens of meters.

The Rosemount Incus Ultrasound Gas Leak Detector utilizes four ultra-sensitive acoustic sensors to provide continuous monitoring and detection of the high-frequency sound waves produced by the release of pressurized hydrogen gas. The device has been engineered to withstand the most extreme conditions and is unaffected by inclement weather, wind, leak direction, and gas dilution or stratification. Sancho explained that the comprehensive coverage provided by this array of sensors makes the device ideally suited to monitoring large areas. He told delegates that at the Cartagena refinery, a single Rosemount Incus Ultrasound Gas Leak Detector provides reliable gas leak detection for an entire compressor shelter.

The post Meeting Safety Challenges in Hydrogen Applications appeared first on the Emerson Automation Experts blog.