High Density Temperature Transmitters in Gasification Pilot

High Density Temperature Transmitters in Gasification Pilot

PlantPlantPatrick Bishop – Chemical Engineerp g

Keith Bentley – Measurement Consultant

PresentersPresenters

Patrick Bishop

Keith Bentley

IntroductionIntroduction

Gas Technology Institute (GTI) recently i i d Ad d G ifi ti T tcommissioned an Advanced Gasification Test

Facility, a research building which houses pilot-scale gasification and gas processing systems.g g g yCritical process measurement points were required to be monitored so data could be collected and analyzed to help verify the process performanceanalyzed to help verify the process performance. The Rosemount 848T high density temperature transmitter and FFMAI blocks in DeltaV were used as a means to effectively achieve this goal.

Gas Technology Institute BackgroundGas Technology Institute Background

Research, deployment and training for the Natural Gas Industry and energy marketsy gy65 years, 1000+ patents, 500 products18 acre campus, 200,000 ft2 of lab and office space50 years of Gasification R&D

Supply-Gasification Research AreaSupply-Gasification Research Area

Increase the use of coal and biomass through the d l t l ti d i li ti fdevelopment, evaluation and commercialization of new gasification technologies.Develop and evaluate new technologies to clean/treatDevelop and evaluate new technologies to clean/treat syngas for various end use applications.Integrate advanced gasification-based technologies

ith d t h l i f d ti fwith end-use technologies for production of power, fuels, and chemicals.

Increasing Energy Supply with Advanced Processes to Convert Coal and Biomass to Power, Fuels, and

Chemicals.C e ca s

GTI’s Flex-Fuel Test Facility (FFTF)GTI’s Flex-Fuel Test Facility (FFTF)A Technology Development and Systems Integration Platform

> Flexible fuel capability

> OperationalOperational flexibility

> Plug and play systems integration y gand testing

Advanced Gasification Test Facility (AGTF)Advanced Gasification Test Facility (AGTF)5-level process research building which houses pilot-scale gasification

d i tand gas processing systems. – Expansion of GTI’s Flex-Fuel Test

Facility (FFTF) Th 13 000 ft2 AGTF id thThe 13,000 ft2 AGTF provides three fully-enclosed process bays with supporting areas and equipment for pilot scale development and testing Carbona biomass-to-liquids (BTL) pilot-scale development and testing of technologies for syngasproduction, processing and end use.

q ( )Pratt & Whitney Rocketdyne(PWR) Advanced Compact Gasifierpilot plantUpcoming Haldor TopsoeUpcoming Haldor Topsoebiomass-to-liquids (gasoline)

Project GoalsProject Goals

The combination of these facilities allows integrated il ti f d d ifi ti d d tpiloting of advanced gasification and downstream

technologies that enable commercialization of better processes to produce power, chemicals, and gaseous and liquid fuels.Built in conjunction with our partners Carbona and Pratt & WhitneyPratt & Whitney– Project timeline and costs were critical factors

Temperature Measurement ChallengesTemperature Measurement Challenges

Need to collect data from over 160 temperature t i t i th ifi ti t dmeasurement points in the gasification reactor and

another 80 temperature points throughout the plant to accurately verify pilot plant performance in a cost y yeffective manner.Working with existing DeltaV – Cabinet space at a premiumpremiumNeed ability to change around devices or move thermocouples as testing dictates.p g

Common Challenges for Projects Implementing Traditional InstallationsCommon Challenges for Projects Implementing Traditional Installations

High costs of i f t t d

Bundled Cabling, Cable Trays, Conduit

infrastructure and equipment

Start-up delays from labor intensive i t ll ti

Extensive wiring and terminations in

h lli bi tinstallations

Unreliable

marshalling cabinets

Unreliable measurement from long sensor wiring runs

S C

Low-level sensor signal

Noise Sources Causing Unreliable Measurement

Traditional Installation ExampleTraditional Installation ExampleMarshalling

Cabinet

System I/OControl room requires large number of I/O cards and marshalling cabinet space. Can be difficult to maintain.

Cable Trays, Conduit, Bundled Cabling

Connectivity hardware increases materials costs and

Junction Box

Junction Box

Analog Transmitters require

increases materials costs and is labor intensive to install.

Analog Transmitters require wiring runs for each measurement. More devices, terminations and wiring infrastructure is required.

Long sensor wires are susceptible to measurement drift.

High Density Temperature Measurement Provides a Cost Effective and Reliable SolutionHigh Density Temperature Measurement Provides a Cost Effective and Reliable Solution

Reduce project costs by reducing wiringby reducing wiring infrastructure

Faster start-ups with fewer devices to installinstall

Improve performanceImprove performance with reliable measurement

Reduce Project CostsReduce Project CostsReduce I/O cards and no marshalling is required. Easier to maintain with no wiring “rats nests.”

Reduce or eliminate connectivity hardware such as cable trays, conduit, and bundled cabling.

As Installed in FieldAs Installed in Field

Faster Start-UpsFaster Start-UpsFewer terminations and less wiring

Fewer terminations and less wire routing to reduce labor effort.

Eliminate individual wiring runs. Reduce the number of devices you install anddevices you install and commission.

As Installed in FieldAs Installed in Field

Improve PerformanceImprove PerformanceMount near the process to reduce risk of measurement drift from electrical noise sources.

Wiring sensors directly to control system is more

848T provides stable measurement in harsh plant

susceptible to measurement drift environments

Noise Sources Causing Unreliable Measurement

As Installed - EnclosureAs Installed - Enclosure

Configuration: Fieldbus SegmentsConfiguration: Fieldbus Segments

Maximum number of devices that can be put on one t i 16segment is 16,

Typical segment design is 8–10 devices per segment, depending on Device Type.depending on Device Type.Function Block Limitations per H1 card (each card can do two segments).– 64 Fieldbus Function Blocks – 32 DeltaV Function Blocks

Configuration: DeltaV FFMAI BlockConfiguration: DeltaV FFMAI Block

Fieldbus Multiplexed Analog Input (FFMAI) Function Bl kBlock– Can process up to eight fieldbus device measurements from

a single device. – Sensor type must be the same

The MAI block can optimize the communications on an H1 segment by providing all of the information foran H1 segment by providing all of the information for up to 8 measurements in a single function block.848T can also allow combination of AI and FFMAI blocks

Example: 4 848T with 31 ThermocouplesExample: 4 848T with 31 Thermocouples

Use of FFMAI BlockUse of FFMAI Block

Macrocycle Time ImprovementsMacrocycle Time Improvements

Configuration: DeltaVConfiguration: DeltaV

Limitation total number of Device Blocks Available.If all AI blocks were used, you would only be able to use a total of 8 848T’s on each Fieldbus Card (8 x 8 = 64 Device Blocks). 64 Device Blocks).Also note the efficiency in the Macro Cycle of the FFMAI as opposed to 8 separate 848T reads by AI1 bl kblocks.

Configuration with AMSConfiguration with AMS

AMS – New Device Dashboards AMS – New Device Dashboards Device Dashboards provide quick access to diagnostics and tell users corrective actions needed to fix issues.

Business Results AchievedBusiness Results Achieved

A critical part of the value GTI offers customers as a h i ti i th bilit t ll t dresearch organization is the ability to collect and

analyze data.By using the 848T, GTI was able to collect data fromBy using the 848T, GTI was able to collect data from over 240 temperature measurement points to accurately verify pilot plant performance for their clients in a cost effective mannerclients in a cost effective manner.

Had spaced to add H1 Card, but not T/C input cardsSaved on wiring costs of home run back to DeltaVg

SummarySummary

Pilot plant challenges required cost effective, flexible l tisolution

– Further complicated by multiple ongoing projects sharing resources

High density temperature transmitters solved many issues with space, time, flexibility and cost constraintsconstraintsGTI now has increased capability to move technology through the critical piloting stage, offering organizations focused on clean energy solutions a platform for systems development.

Where To Get More InformationWhere To Get More Information

www.gastechnology.orgHigh Density Temperature Sessions at Emerson Exchangewww emersonprocess comwww.emersonprocess.com– Rosemount Temperature High Density Temperature– DeltaV

Your local Rosemount Instrument ConsultantYour nearby Emerson Local Business Partner