Rosemount 3051S

Electronic Remote Sensors

A Digital Upgrade to a Proven Technology
 DP Level is a Proven and Successful
Technology
Process Level Market
Pressure by Technology*
Level 
Specific Gravity Other
26% DP 30%
 Straightforward measurement technique
 Easily verified and calibrated Ultrasonic
 Flexibility enables use in variety of 12%
Radar
applications (mass, density, interface) Switches 17%
15%
3051S ERS Tuned-System Balanced System Wet Leg Dry Leg

[File Name or Event]

EmersonSlide 2
Confidential
*VDC
27-Jun-01, Slide 2 Global Process Level (2005), ARC Global Radar Study (2008), F&S Global Level Sensors (2005)
New 3051S Electronic Remote Sensors
Enhance DP Level Technology

PLO DP Calculated Electronically

• Two Pressure Sensors
• Electronics Featureboard

Wire
Utilizes Proven 3051S
Sensor Platform

DP = PHI – PLO
4-20 mA Two-Wire 4-20 mA Output
with HART
PHI

[File Name or Event]

EmersonSlide 3
Confidential
27-Jun-01, Slide 3
3051S ERS Provides Additional DP Level
Capabilities
Simplified
PLO
Installations

Improved
Performance
Wire
Simplified
Maintenance &
DP = PHI – PLO Spares Inventory

4-20 mA
Access to New
PHI Information

Synchronized &
Integrated Solution
[File Name or Event]
EmersonSlide 4
Confidential
27-Jun-01, Slide 4
 3051S ERS Simplifies Installation Practices
1. Independently install each sensor
1 – Direct-mount without pipe stand, brackets,
and other hardware
– Can be installed by a single instrument tech
2. Wire sensors together
2 – Non-proprietary electrical wire
– Easy to install around catwalks, on
distillation columns, etc.
– Eliminate insulation and heat tracing
3. Perform a system zero trim
1
3 – Establishes true zero-based DP measurement
– No zero elevation calculation required

3051S ERS Architecture Supports Flexible Installations

3051SAM 3051SAM with

Featureboard
Remote Display
with Featureboard 3051SAM with
3051SAL with 3051SAL
[File Name or Event] level flanges
Featureboard
EmersonSlide 5
Confidential
27-Jun-01, Slide 5
3051S ERS Digital Architecture Delivers
Improved Performance
Direct Connection to Tank Reduces Time Response

Transmitter with Direct-Mounted

10 ft (3 m) Capillary ERS Transmitter
Digital Architecture Eliminates Measurement Drift
Wet Leg Dry Leg Capillary 3051S ERS
System
Evaporation
Electrical Wire

Condensation

Fill Fluid Density & Digital architecture

Volume Changes with eliminates temperature
Temperature effects

[File Name or Event]

EmersonSlide 6
Confidential
27-Jun-01, Slide 6
3051S ERS Simplifies Maintenance and
Spares Inventory
Replace one transmitter vs.
entire capillary assembly
Simplify spares inventory &
standardize on common ERS
components

• Corrosion
• Process-coated diaphragm
[File Name or Event]
EmersonSlide 7
Confidential
• Hydrogen permeation
27-Jun-01, Slide 7
3051S ERS Provides Greater Insight Into
Your Process

Automatic & Monitor PHI and PLO

synchronized DP pressures in real-time
calculation

Process alerts enable

proactive maintenance
practices

Scaled Variable
converts DP into
level & volume
measurements

[File Name or Event]

EmersonSlide 8
Confidential
27-Jun-01, Slide 8
20-Point Scaled Variable Simplifies
Configuration & Commissioning
Automatically convert DP into level, volume,
mass, or other variables
3 Easy Configuration
Options

1 Direct
• Manually provide up to 20
“DP vs. Scaled” pairings

25 mbar = 17.9
2 Tank Formulas LITER
• Scaled Variable using basic
tank dimensions

3 Strapping Table
• Scaled Variable using tank
strapping table
[File Name or Event]
EmersonSlide 9
Confidential
27-Jun-01, Slide 9
 3051S ERS Provides an Easy, Integrated
Solution
Do-it-Yourself (Two Transmitters) 3051S ERS
PLO
P2
P1

∆P P2 No error from ∆P
change in static
pressure (∆P)

DP DP
P1 PHI

• Not synchronized • Synchronized measurements

• 2x wiring costs • Single 2-wire 4-20mA loop
• 2x required I/O • No DCS programming
• DCS programming • Easily zeroed & calibrated
•[FileDifficult to “zero” DP
Name or Event]
EmersonSlide 10
Confidential
27-Jun-01, Slide 10
Chevron Phillips Chemical (Borger, TX)
Achieved Success with 3051S ERS
 CHALLENGE
– Bridle with magnetic float and unreliable
heat tracing
– False level measurement & unplanned
shutdowns
 SOLUTION
– 3051S ERS easily retrofitted entire bridle
assembly
– Digital architecture eliminated need for heat
Application tracing
• 30 ft (9 m) process
storage tank
 RESULTS
• Ambient Temp – No unplanned shutdowns since installation
0 to 100 F of 3051S ERS (3+ years)
(-17 to 38 C)

“We have had no lost production and better on-stream operation since installing ERS”
- Tim
[File Name or Event] Anderson, I&E Reliability Team Leader, Chevron Phillips Chemical, Borger, TX
Emerson Slide 11
Confidential
27-Jun-01, Slide 11
Oil Refinery Eliminates Unplanned
Shutdowns on Reactor with 3051S ERS
 CHALLENGE
– Frequent, unplanned plant shutdowns
– Caused by plugged lines on pneumatic
transmitter with wet leg
 SOLUTION
– 3051S ERS assembly with FFW
flush flanged seals
 RESULTS
Application – 100% measurement reliability since
• Alkylation reactor installation (3+ years)
• Level measurement – No work orders or requests for
of effluent liquid troubleshooting

The 3051S ERS assembly with flanged seals was easily retrofitted on the
Alkylation reactor and eliminated unplanned process shutdowns.
[File Name or Event]
Emerson Slide 12
Confidential
27-Jun-01, Slide 12
Austrian Pulp and Paper Mill Decreases
Maintenance Costs with ERS Technology
 CHALLENGE
– Excessive maintenance costs on wet leg
installation
• Plugged lines
• Heat tracing
• Vacuum spikes
– Suboptimal black liquor output
 SOLUTION
– 3051S ERS system
 RESULTS
Application
– Elimination of heat tracing and water
Level measurement
purging
on black liquor vessel
– Increased reliability and repeatability of level
measurement

Zellstoff Pöls Austria was able to address reoccurring maintenance problems and improve
[File Name or Event] their level measurement by upgrading to a 3051S ERS system.
EmersonSlide 13
Confidential
27-Jun-01, Slide 13
Pulp and Paper Mill Reduces Downtime
with Digital 3051S ERS Architecture
 CHALLENGE
– Approx. one unplanned shutdown per month
– Pump cavitations
– Reoccurring problems with wet legs
• Plugged impulse lines
• Maintaining level in wet leg

 SOLUTION
– 3051S ERS system
 RESULTS
Application – Elimination of wet leg
Vacuum tank on lime – Only one shutdown over 2-year period
mud filter
– Process runs in automatic close to 100% of
time

“The continued uptime with this instrument has built operations’ confidence in the
measurement itself and has allowed the process to be run in automatic close to 100% of
[File Name or Event]
Emerson Slide 14
Confidential the time”
27-Jun-01, Slide 14
Biotech Facility Increases Throughput on
Fermentation Vessel with 3051S ERS
Application
Level measurement
on enzyme
fermentation vessel
 CHALLENGE
– Inconsistent batches
– 3-5% measurement error
– Unable to calculate yield
 SOLUTION
– 3051S ERS system with hygienic Tank-
Spud seals
 RESULTS
– Measurement error improved to less than <
0.5%
– Drastic time response improvement
– Achieved consistent, high-quality batches

“This application used to be our biggest headache, but now the

fermentor is used as our first choice depending on the quality of
[File Name or Event]
product needed.”
Emerson Slide 15
Confidential
27-Jun-01, Slide 15
Solvay Decreases Operations &
Maintenance Costs with 3051S ERS
 CHALLENGE
– Costs and challenges associated with DP
transmitter and wet leg installation
• Salt crystals would plug impulse lines
• Required complicated water injection system
• Evaporator had to be taken off line frequently

 SOLUTION
– 3051S ERS with EFW extended diaphragm
seal
 RESULTS
– Extended seal used at bottom of tank
eliminated plugging
Application – Digital architecture enabled optimized
• Brine level control
measurement
• 33 ft (10 m) “The ERS system has been
evaporator installed for months, much to our
total satisfaction”
[File Name or Event] - Jean-Marc Deconto, Solvay engineer
Emerson Slide 16
Confidential
27-Jun-01, Slide 16
Chemical Company Eliminates Excessive
Maintenance Costs with 3051S ERS
 CHALLENGE
– Excessive maintenance costs:
• Troubleshooting dry leg installation
• Daily field visits to check distillation packing
– Measurement drift from temperature variations
 SOLUTION
– 3051S ERS system

Application  RESULTS
20 ft (8.3 m) Glycerin – No unplanned shutdowns for over one year
refining tower – Able to accurately monitor health of packing in
tower without manual trips to field
– Eliminated costs associated with
troubleshooting installation

“Since installing ERS, we never hear any complaints from our

maintenance or operations group. As far as I am concerned, no
news is good news.”
[File Name or Event] - Project engineer
Emerson Slide 17
Confidential
27-Jun-01, Slide 17
Silicon Manufacturer Reduces Inventory
Costs with 3051S ERS
 CHALLENGE
– Excessive capillary caused measurement
error > 5%
– Inconsistent batches
• Material shortages
• High scrap rates

 SOLUTION
Application – 3051S ERS system
Level control in silicon
 RESULTS
holding tank
– Accurate level measurement
– Achieved consistent batches
– No unplanned shutdowns

The long lengths of capillary with the previous installation were

completely eliminated with the digital architecture of the 3051S
[File Name or Event]
ERS system.
Emerson Slide 18
Confidential
27-Jun-01, Slide 18
 New 3051S Electronic Remote
Sensors Have Proven Successes

Proven ERS ERS Applications

Applications Characteristics
1. Distillation Tower • Tall Spans
2. Chemical Holding Tank • Temperature Variation
3. Enzyme Fermentation • Heat Tracing
4. Batch Tank 3051S • Plugged Impulse Lines
5. Vacuum Tank ERS • Low Static Pressure
6. Chemical Reactor System • Excessive Impulse
7. Black Liquor Level Piping / Capillary
8. Beer Storage • Measurement Drift
9. Glycerin Refining
10. Starch Level

[File Name or Event]

Emerson Slide 19
Confidential
27-Jun-01, Slide 19
 3051S ERS Compliments Traditional DP
Level Technology
Electronic Remote Sensors
• Sensors sized on amount of static
100 pressure + DP column
100
• GP Sensor Span = 103.6 psi psi
PSI (2868 in.H20)

Tuned-System™ Assembly
• Sensor sized on DP column only 100
100 • DP Sensor Span = 100 in.H20 in.H20
in.H20

High Pressure Application Example

ERS Tuned-System
VS
±2.8 in.H20 ±1.4 in.H20

25 F Ambient Temperature Change

[File Name or Event]

Emerson Slide 20
Confidential
27-Jun-01, Slide 20
 Traditional DP Level Technologies Still
Have Key Applications and Benefits

Traditional DP Level Application

Technologies Characteristics
• Tuned-System • Short Spans
Assembly • High Pressures
• Balanced Capillary • Indoor Vessels
System • Stable Temperatures
• DP transmitter with wet • Simple Installations
leg • Wireless
• DP transmitter with dry
leg

Tuned-
System
Assembly
[File Name or Event]
Emerson Slide 21
Confidential
27-Jun-01, Slide 21
Achieve Success with Rosemount DP Level
in More Places than Ever Before

Measurements Applications Industries

[File Name or Event]

Emerson Slide 22
Confidential
27-Jun-01, Slide 22