Perspectives 15 Metal En

7/28/2019 Perspectives 15 Metal En

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Issue no. 15

Metal Industry perspectives

Robust and reliable

Safety coupled with intelligence

Developed and manufactured in accordance with

SIL/IEC 61508 (Safety Integrity Level). The

integrated Histo-ROM/M-DATrecords and saves the most impor-

tant process and device parameters

at all times. Using the ceramic dif-

ferential pressure transmitter, the

smallest measuring ranges in the

Pascal range (+/- 0.5 mbar) can

be measured accurately and in a

reproducible manner (e.g. furnace

pressure applications).

More information can be found at

www.us.endress.com/pmp71

www.us.endress.com/pmd70

Temperature measurement without

heat stress

Resistance thermometers or thermocou-

ples measure process temperatures, and

the head transmitters from the iTemp

TMT18x range ensure safe and accurate

transmission. Top-hat rails and eld trans-

mitters are also available.


www.us.endress.com/temperature

A fresh approach to measured value

reliability

The 6 GHZ Micropilot M FMR44

process radar devices are a cost-effective

alternative for smaller measuring ranges

in bulk solid applications. They are used

in small silos that are lled to their maxi-mum capacity.

Measuring range up to 15 m in bulk solids

Process temperature -40 C to +80 C

Fully encapsulated PTFE disk antenna

Variable process connection with slip-on ange

or mounting clamp


www.us.endress.com/fmr244

Process solutions 2

Leakage monitoring online analysis

Alarm function

Online Analysis

Project expertise 3

Modernization of blast furnace stock line and

profile level measurement

Stock management

Reducing process costs 4

Memosens technology

Unlocking the savings potential

Optimizing processes 5

Modernization of acid storage facility

Density measurementSelection tools

Managing and organizing

information 6

Fast access to information

Service is the key advantage

Did you know ...?

One-stop shop for process

automation and solutions"Tough requirements and maximum safety

are the driving forces in our business.

Measurement technology in integrated steel work plants

must operate reliably, even under extreme conditions.

Measuring devices must be capable of withstanding

mechanical stress, extreme temperatures and aggressive

media. Endress+Hauser has many years of on-the-job ex-

perience in the metal industry, and has a team of suitably

qualied experts on hand to assist our customers.

The perspectives editorial team spoke to Jens Hundrieser, Global

Industry Manager for Metals and Primaries, about Endress+

Hauser's measurement and automation technology and trends in

the metal industry.

Application Example

Level measurement at a gas holder

Level measurement with non-contact radar and

implementation of sensors in accordance with SIL

Three level transmitters are installed at a gasometer with

a metallic oating cover which is held in place by several

supports arranged around the perimeter.

The three Micropilots FMR30 with a DN 50 horn arealso distributed evenly around the perimeter. The signal

is reected onto the oating cover by metal surfaces

which are welded on to the side.

Jens Hundrieser,Global IndustryManager for

Metals andPrimaries atEndress+Hauser

More than ever before, the econo-

mic situation is forcing companies

in all industries to become more

cost-conscious in terms of their pro-

duction. What is Endress+Hauser's

response to this?

We identied this trend towards cost

reduction some time ago. Generally

speaking, we took a look at which cost

reduction solutions we could propose

to our customers, particularly in theareas of raw material usage, process

optimization and energy consumption.

An example would be a test station for

air compressors, which reduces main-

tenance times and downtime.

Is it possible to discern any trends at

the moment which are of relevance

to measurement technology?

Yes, most denitely. Functional safety

SIL/IEC 61508 (Safety Integrity Level)

is growing in importance in the area

of metal production. We are respon-

ding to this trend with SIL-approved

measuring devices, tailored consulting

and training courses all about SIL.

This obviously includes the design and

documentation of safety functions in

chemical plants as well as in furnaces,

burner equipment and also gas holders(see example below). The safety of

people and the installation is of course

of vital importance. Leakage monito-

ring in cooling circuits of electric arch

furnaces increase the safety

At Endress+Hauser, marketing and

sales are organized by industries.

What does this mean?

As "people for process automation,

we must understand our customers

and be aware of their needs. Our team

of industry managers is always on the

lookout for possibilities, market shifts

and trends, in order to guarantee the

success of our customers into the fu-

ture. They are responsible for adopting

and implementing the right strategy for

each industry. In addition, we cultivate

area-wide networks for each industry,

together with regional and internati-

onal industry managers and external

industry representatives.

Environmental protection is also an

important topic in the metal indus-

try. Does measurement technology

have a contribution to make here

too?

Environmental protection is always a

topic of discussion whenever emissi-ons are to be monitored or wherever

process water and wastewater arise.

It is in this area in particular that our

range of liquid analysis technology is

put to use.

Can customers continue to rely on

Endress+Hauser after purchase?

In addition to proper planning, key fac-

tors in ensuring the continued success

of the measurement process are cor-

rect commissioning and maintenance

of the sensors.

As well as having detailed knowledge

of the sensors, Endress+Hauser's

trained service technicians are familiar

with the particularities of the industry

and the different applications and

will carry out these and many other

services.


2/6

Process solutions

Endress+Hauser perspectives

Integrated steel works have numerous safety-rele-

vant water cooling circuits. These include, for exa-

mple, tuyere cooling at the furnace, lance cooling at

the converter and water cooling of the panels at the

electric arc furnace. These cooling circuits dissipate

process heat, thereby preventing thermal damageto plant equipment. Any leakages here may give

rise to explosions due to water coming into direct

contact with molten metal, thereby presenting a risk

to people and machinery. Reliable monitoring and

fast reaction times are key factors in ensuring that

avoidance measures, such as removing the affected

system component from the cooling system, are

taken.

Leakage detection at the blast furnace

In furnace applications, nozzles are arranged in a ring

around the furnace wall and used to inject a hot blast at

a temperature of 1200 C into the furnace in order to re

it up. Each tuyere in the furnace is equipped with a water

cooling device. Nonetheless, the hot melt puts a strain on

the tuyeres, resulting in recurring leakages. This is how

water gets into the furnace. While it may be hard to ima-

gine in the case of such an enormous volume of pig iron,

even a couple of liters of water may affect the reduction of

air to carbon monoxide.

For reliable monitoring, an electromagnetic owmeter

(Promag) is installed in both the supply and return lines of

a tuyere, to enable continuous measurement of the cooling

water ow rate. As soon as the ow rate differential ex-

ceeds the computed limit value, an alarm is triggered.

Leakage detection at electric arc furnaces

Several cooling circuits pass through the electric arc

furnace. A malfunction here might not only damage the

process, but could also be detrimental to the furnace

itself. Leakages here tend to occur primarily in the furnace

chamber. When implementing ow measurement, it is

important to differentiate between DC and AC electric arc

furnaces. For leakage detection purposes, electromagnetic

owmeters are used in all circuits in the case of AC fur-naces, while inline or clamp on ultrasonic devices are used

in the case of DC furnaces.

In general, the two cooling circuits in the "roofs" and "pa-

nels" are tted out rst. If the measurement results deviate

from the dened limit values, the responsible positions are

notied immediately.

A complete package for leakage detection

Typically, electromagnetic owmeters are used. The

electronically remote version of these devices is selected in

order to bypass ambient temperature effects. The tem-

perature increase in the return line results in a change in

density which is taken into account when measuring. Thiscan be corrected using two temperature sensors which are

mounted at a suitable point in the circuit.

The accuracy of the owmeters depends on the nominal

diameter of the piping and the ow velocity. The devia-

tions being detected must be within the range of measure-

ment uncertainty of the devices. Under ideal conditions,

this would be +- 0.3 %. In practice, typical accuracy levels

for the leakage volume of the entire system are approx.

0.8 % of the nominal ow rate for the supply and return

lines. In the case of ow rates of 200 and 300 m/h, for

example, leakages of 1.6 to 2.4 m/h are reliably detected.

Experience has shown that in order to prevent false

alarms, an alarm should not be triggered until a tolerance

time limit has elapsed. For example, an alarm is triggered

if a deviation of 50 l/h occurs for longer than 90 seconds.

Central access with PROFIBUS

To meet the requirements for accuracy and safety, all sen-

sors are connected to the PROFIBUS PA eldbus. This not

only reduces the amount of wiring, but also guarantees the

transmission of measured values with their status for error

messaging, as well as ensuring maximum accuracy due to

the elimination of A/D signal conversion.

Fieldbus communication facilitates central access for main-

tenance and conguration work. Due to the star-shaped

wiring of the sensors, it is possible to remove individual

cooling water lines without disabling the entire bus

system. This may be necessary in the event of a fault or

if a device needs to be replaced, . However, digital signal

processing on its own is not sufcient. The arrangement of

the sensors is a key factor in securing a satisfactory result.

Endress+Hauser supplies the complete package for leakagemonitoring. It is ready to use and includes a PLC with pro-

gramming of analyses and calculations, a control cabinet,

mounting, wiring as well as commissioning of the devices.

Beside the standard package for leakage monitoring

Endress+Hauser also offers a solution according to

DIN EN ISO 13849-1:2007.

Leakage monitoringEven the smallest amount of water entering the furnace can have disastrous con-

sequences. Flow and temperature measuring devices ensure prompt detection of

leakages.

Leakage monitoring at the blast furnace using Promag electromagnetic owmeters

Alarm function silenced

Monitoring the ow rate of cooling water is a criti-

cal factor when it comes to safety. This has been

acknowledged not just by the Norwegian autho-

rities. The requirements for ow monitoring

have now become stricter. Elkem, a Norwegian

company producing aluminum and metal, was

consequently tted out with new measurement

technology.

The key problem in cooling water circuits is the slow re-

action time and the increase in temperature in the return

line due to the low rate of ow. As a result, It is extre-

mely difcult to distinguish leaks from other problems.

In this regard, inline ultrasound measuring devices offer

a promising solution. The ultrasound measuring devices

were chosen as they are not affected by the very high

electric eld strengths present in the area surrounding

the electric arc furnace.

Endress+Hauser supplied several hundred Prosonic Flow

92F ultrasound owmeters with PROFIBUS PA interface

to Elkem. These are used in safety-critical applications

for monitoring cooling water circuits in steel furnaces. If

the ow rate in the return line falls below a certain level,

an alarm is activated immediately. Thanks to PROFI-

BUS communication, additional information such

as sonic speed and signal strength is available. These

parameters provide conclusive information concerning

deposits, boiling or trapped air.

Elkem is very impressed with the functional safety of the

devices. In total, more than 500 measuring devices have

been ordered for all plants.

Increased plant availabilitythanks to online analysis

Buildup and corrosion are known to have a detri-

mental effect on pipes, cooling circuits and entire

plants. By bearing this in mind and taking prompt

action, plant availability can be increased signi-

cantly.

Thyssen-Krupp in Duisburg is only too aware of this

problem in cooling circuits. That is why they monitor

the parameters relating to buildup, including phosphate,

silicic acid and hardness, as well as the corrosion-indu-

cing substances chloride and hydrazine.

In the past, this involved taking samples manually on a

daily basis and analyzing them in a laboratory. However,

either the results were not sufciently up-to-date for the

company, or process measurements were used whichwere not sufciently accurate.

That is why they switched to online analysis using 1

Stamolys measuring devices from Endress+Hauser.

Up-to-date measured values are now available every 10

to 15 minutes, meaning that action can now be taken

in realtime. This not only increases process safety, but

enables better quality management.

Prosonic Flow inline ultrasonic owmeters in cooling water

circuits at DC electric arc furnaces

CA71 analyzers used for cooling water


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Endress+Hauser perspectives 3

Project expertise

The furnace was already ripe for the scrap heap.

A blast furnace usually requires relining after approximately

twenty years of continuous operation. This was the case

with one of the two giants in Fos-sur-Mer. It was when

planning the new construction that the need for new mea-

suring devices emerged. In the process, the furnace was

to be digitized. Nowadays, if you want to know which

part of your car is defective, the rst thing a mechanic does

is boot up the computer. Thats exactly what we want to

be able to do in the future, explained Alphonse Fabiani,

electrical engineer at the Fos-sur-Mer plant.

To control the pig iron production process digitally, the

automation technology and measuring devices used must

be highly robust and reliable in order to withstand the ex-

tremely tough conditions. The project scope comprised

the delivery of approximately 1,200 eld devices including

periphery (400 were implemented using PROFIBUS PA), aswell as instrumentation engineering. The package also

contained the supervision of mechanical and electrical

works and training on site, the PROFIBUS conguration,

platform test and support of the integration in Siemens

PCS7 (PDM)

"We need solutions, not someone who just passes

the buck (... )

From Mr. Endress to the technician, the entire

Endress+Hauser team was very committed, replied Phi-

lippe Divol from ArcelorMittal when we asked him about

his experience of working with Endress+Hauser.

Our partnership with Endress+Hauser has paid off for the

plant in every respect: the cost of hiring new specialists

at ArcelorMittal and training them to work for the steel

giant would have been signicantly more than the cost of

the complete package from Endress+Hauser. The risk of

production downtime has also been reduced. After only 90

days, steel production was running to schedule again. Each

additional day would have resulted in average prot losses

of 3.5 million Euro. And that's not all.

Thanks to the PROFIBUS

technology which was installed,technical processes are now resulting in better control,

which in turn reduces operating and maintenance costs.

Endress+Hauser was there from the start.

The company took Endress+Hauser on board four years

prior to the planned relining project, and decided to form

a partnership. For the staff at Fos-sur-Mer, the reasons be-

hind their decision were obvious: Endress+Hauser's broad

range of technical expertise, their exibility and creative

thinking, their long-standing business relations and an

ability to react quickly to events as they occur.

Another factor was the competitive price of the solution

package coupled with PROFIBUS technology.

Endress+Hauser was head of a consortium and was respon-

sible for managing the entire project from planning

through to engineering and commissioning.

ArcelorMittal has already commissioned Endress+Hauser

with upgrading the second blast furnace in Fos-sur-Mer.

The project is practically identical to the rst one, with thesame team and exactly the same project scope. This is testi-

mony to the great partnership between ArcelorMittal and

Endress+Hauser and proof that the best possible solution

was delivered.

Modernization of anold giantBlast furnace completely revamped in three months

ArcelorMittal, the largest steel producer worldwide, generates around one tenth of the

world's steel. The company continuously works to improve its competitiveness. Cur-

rent processes are optimized and new approaches developed with the aim of reducing

costs and improving quality. This was precisely what they hoped to achieve by moder-

nizing a blast furnace located at their plant in Fos-sur-Mer. Approx. 4.5 million tons of

steel are produced annually using two blast furnaces. With professional support from

Endress+Hauser, the furnace was revamped in record time. Blast furnace at ArcelorMittal Fos-sur-Mer

Stock line measurement:

For charging purposes, it

is essential that the axially

symmetric bulk goods

process be monitored when

lling with a rotating chute

and that positioning be

controlled.

Solution: Installation of

three radar sensors in a radi-

us, at 10 degrees intervals (three sectors in the blast

furnace), as a replacement for mechanical sensors.

Prole recording

Using prole information to inuence the bulk goods

of material per dened ring segment (e.g. eleven rings)

in the blast furnace.

Solution: Installation of ve

radar sensors at the furnace

head, which measure the

level along a radius. Using

these data, the discharge

prole can be roughly de-

termined across ve support

points. While the accuracy

is not as good compared

to a conventional prole

sensor, the advantages are

as follows:

Continuous measurementProle information is

always available

No disruption to loading and

no change in stock line due to sensor movement

Lower maintenance costs

Radar is also used for level measurement of pig iron in

the torpedo car.

Inventory management solution

using Control Care

One package solution with a total of 100 non-contact

radar sensors in two integrated steel work plants

belonging to the Shougang group in China.

Scope:

ControlCare Field Control-

ler SFC173 with local I/O

modules

SCADA softwareControlCare P View

FieldCare standard opera-

ting software (FDT-based

tool for plant-based

Asset Management)

100x Micropilot M

FMR50

Using radar to measure stock line

and prole levels in blast furnaces

Package solutions including engineering and commissioningBlast furnaces must be tted with at least two depth indicators which work independently of each

other. One of them automatically records stock line level on a continuous basis. In addition, prole

recording is growing in importance.

ControlCare Field Controller (above), radar sensors installed in the

bunkers (below)

Depth measurementusing radar sensor.

Prole recording usingradar sensors.


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4 Endress+Hauser perspectives

Reducing process costs

4 Endress+Hauser perspectives

There's no messing around with sulfuric

acid. This is something that Gerd Reimann,

operations engineer involved in surfacenishing at Salzgitter Flachstahl, is well

aware of, as is Henning Borchers, manager

of instrumentation and control technology

for the internal service provider.

The measuring devices used are perma-

nently exposed to aggressive environmental

conditions and are therefore extremely

vulnerable. At least this was the case with

pH measuring points up to now. They play

a key role in the product quality and, in the

past, were a strain on the budget due to the

high costs associated with their purchase,

maintenance and repair.

How things used to be

The old method of pH measurement com-

prises a container with a single electrodeand a reference electrode, in addition to a

diaphragm lled with a potassium chloride

solution. On top of the container is an

amplier with four contacts, which oxidize

quickly and may cause problems. In addi-

tion, the system incorporates an internal

temperature sensor. As the system used did

not close tightly, aggressive liquids which

sometimes dripped onto the housing,

slowly destroyed connections, cables and

electrodes.

"To guarantee correct measurement,

someone has to remove the electrode on

site, clean it, immerse it in a buffer solution

and calibrate the amplier, explains

Borchers. The same procedure is then

repeated with buffer solution number two."

In the past this sometimes took one hour to

do. (...) What appealed to me most about

Memosens was the encapsulated electrode.

You can spill acid on the plastic housing

without any cause for concern, says Rei-

mann happily.

Is the changeover nancially

worthwhile?

Although relatively high costs are incurred

initially due to the modications required

to the pipework, these are rapidly absorbedby the savings achieved. On the one hand,

the E+H system is already substantially

cheaper to buy. On the other hand, the old-

style pH measurements were costing us up

to 5,000 Euro per week including materials

and labor. That adds up to 100,000 Euro

per year, says Reimann. It is no surprise,

therefore, that in the last two years Salz-

gitter Flachstahl has gradually switched its

plant over to Memosens.

These days, Reimann keeps only three of

these new sensors in stock as spare parts.

Incidentally, the reliability of Memosens

means that plant availability is increa-

sed and the internal service provider's

workload in the area of surface nishing is

reduced to a minimum.

Unbreakable technology

According to Reimann, another key benet

of Memosens is that the electrode does

not have to be calibrated at the trans-

mitter where it is used: "Calibration can

now be carried out at a central location."

This means that there is no need to go

on site, which results in signicant cost

and time savings. Furthermore, any work

processes that can take place outside the

plant enhance workplace safety, Reimann

explains. This is why Salzgitter Flachstahlhas purchased a slimmed-down transmit-

ter specially for the laboratory on which a

laboratory technician can now calibrate the

electrodes in passing. This takes just 20

minutes per electrode.

We have been looking for alternatives

for a long time now, and have really tried

everything in the last 0 years. But there

was nothing else. The breakthrough nally

came when we tried Memosens from

Endress+Hauser, Reimann points out.

More information at

www.us.endress.com/

memosens

Memosens technologySix-digit cost savings thanks to digital pH sensor

pH measurement using the Liquisys M transmitter and a digital electrode with Memosensconnection

In the different industrial segments of the iron and

non-iron industries, savings trends can be identied

in two main segments: utilities or auxiliary circuits

with steam, compressed air, natural gas, water and

electricity; and industrial gases such as N2, O

2, H

2,

argon and CO2

.

Example of savings: argon dosage

One of several practical examples of how to reduce costs

and achieve savings is bottom blowing of argon/nitrogen

coupled with mass ow and pressure monitoring, as for

example in steel works. In this eld of application, highly

accurate mass ow measurements are achieved with

the help of Coriolis owmeters combined with pressure

sensors and a eldbus system such as PROFIBUS PA. The

replacement of conventional pitot tubes resulted in savings

in gas consumption, as greater accuracy resulted in better

process control through the smaller measurement window.

Instead of at least 1 % of the measured value plus conver-

sion error and creeping losses in conventional measure-

ment, 0.35 % of the (current) measured value (mass) is

now achieved. For this reason, dosing is now much more

precise, resulting in cost savings of a ve digit number

Euro range.

Example of savings: compressed air leak detection

Compressed air networks are another starting point for

achieving cost savings. In a steel works plant, approxima-

tely eight percent of the energy requirements are for

compressed air. To generate 1 kWh of compressed air,

approx. 7 kWh of electricity are required. The industrial

cost of compressed air is approx. 0.75 Euro per kWh. With

leakage losses of up to 30 percent, this is an area with

massive savings potential, which can be fullled through

process automation.

Measure rst, then improve

The way to approach any kind of optimization is rstly to

obtain transparency with regard to the processes affected.

For this reason, it is essential that data be collected at closeintervals and subsequently analyzed. Greatest savings

potential can be identied on this basis. With the precon-

ditions of the transparency of the energy consumption

and the raised awareness of the employees experience has

shown that an Energy Monitoring System saves 5 to 15

percent of the annual energy costs. As an initial approxi-

mation, 8 percent appears to be a reasonable estimate

Saving energy with Endress+Hauser

Due to increasing energy costs, both customers and

suppliers have an interest in veriable and accurate

energy balancing and invoicing.

Endress+Hauser provides the following

services in process and auxiliary circuits:

Energy monitoring

Leakage monitoring of steam, com-

pressed air

Consumption monitoring of argon,

steam, compressed air, N

Efficiency determination:

steam boilers, heat exchangers

For energy measurement in utilities, a

solution is provided which can be calibrated

and veried on site. This includes suitable

measurement technology, total accuracy

calculation and verication.

New, modern and innovative are three attributes which have become somewhat

hackneyed. However, they most certainly apply to Endress+Hauser's digital

Memosens technology, which is resistant to moisture, dirt and high electric elds

and does not require eld calibration. It also increases plant availability and is

incredibly well priced and inexpensive to operate. The pH sensor has been used

in the electrolytic galvanizing of the surface nishing process at Salzgitter Flach-

stahl where it has proven itself capable of meeting all expectations, even in the

toughest operating conditions.

Unlocking the savings potentialMore efcient usage of raw materials and energy or a reduction in emissions - there are great savings to be made through

investment in adapted automation solutions

In this application,highly accuratemass owmeters in

accordance with theCoriolis principle areused together with

pressure sensors devices with digitalcommunication inPROFIBUS PA ensure

the highest level ofaccuracy.


5/6

Endress+Hauser perspectives 5

Process optimization

A holdup in the pickling process could result in a

production stoppage across the entire cold rolling

mill. This was a risk that ArcelorMittal Eisenhtten-

stadt GmbH was by no means willing to take. For

this reason, the acid storage facility in the regene-

ration area was upgraded to ensure the continuous

supply of pickling line.

To ensure trouble-free, continuous operation, it is of vital

importance that faults are diagnosed quickly and reaction

times reduced. In order to achieve this objective, the up-

grade focussed on two aspects. On the one hand, a central

visualization system for the production process was to be

set up in the regeneration switch room to allow for better

observation and monitoring, including tracking of quanti-

ties and levels. On the other hand, the rapid procurement

of spare parts was to be guaranteed, in order to ensure

maximum plant availability.

Technology at work for ArcelorMittal

Intelligent eld devices form the basis for optimum process

control coupled with a modern maintenance and repair

strategy. In this project, radar measuring devices (type

FMR45) and vibration limit switches (type Liquiphant

FTL51) were used for level measurement. Electromagnetic

owmeters (type Promag 50P and W) were used, as were

vortex meters (Prowirl 7 ) for compressed air measure-

ment. Pressure measuring instruments (Cerabar M) and

Pt100 resistance thermometers TR13 were also used.

The PROFIBUS PA system is connected via a PROFIBUSDP card to a Siemens S7 controller. The Wonderware

Intouch system is used as the human machine interface.

Based on the FDT/DTM standard, nonproprietary, open

conguration and diagnostic tools are being used to an

increasing extent for measurement and control technology.

ArcelorMittal uses FieldCare from Endress+Hauser both

for commissioning and as a service tool. When diagnosing

errors, several dened error messages now accumulate in

the visualization system. Due to the differentiation of ope-

rational requirements for maintenance and repair services,

it is possible to decide using sensor diagnostic information

whether a problem relates to a measurement technology

device or a fault in the process.

"W@M always provides reliable information

From engineering to procurement, commissioning, operati-

on, maintenance and the replacement of individual compo-

nents, the W@M-Portal (Web-Enabled Asset Management)

provides up-to-date and complete information. In the case

of Endress+Hauser devices, technical data, documentation,

product status, spare parts lists and events from the life

cycle are made available automatically.

In conjunction with a classication of critical measuring

points and the maintenance risk involved, recommenda-

tions are made regarding spare parts procurement. The re-

sult is guaranteed plant availability, streamlined spare parts

management and an associated reduction in xed capital.

The W@M-Portal displays all the data via a standard

browser, thereby eliminating the need to install and main-

tain additional software.

This means that customers can have round-the-clock

access to plant-related information from any internet-com-

patible PC.

Operational experience

From the modernization of an acid storage facility

in the cold rolling mill (CRM) at ArcelorMittal.

Micropilot FMR245 level transmitter

Density measurement in a spray

roaster

To optimize the roasting process in the

regeneration, density measurement is used

to determine density in the more highly

concentrated utilized acid. The measure-

ment records the density of the concentrate

and prompts the addition of rinse water to

the circulated concentrate via switch points

determined by the operator. This prevents

the spent acid from becoming overconcen-

trated and crystallizing.

The medium to be measured is a highly corro-

sive mixture of hydrochloric acid (0 % - 33 %),

iron (II) chloride, iron chloride, iron oxide and

silicon oxide, and places enormous demands on

the measurement technology. The density varies

from 0.95 g/cm to 1.5 g/cm, the process tem-

perature runs between 9 and 95 C, and the

pressure range varies from 0 to 5 bar. The ow

velocity is m/s.

The objective was to nd a reliable and accurate

way of measuring density with a view to repla-

cing the two manual measurements taken daily

in a laboratory. Of particular importance was ahigh degree of reproducibility, with measured

values comparable to the laboratory values, if

possible.

The Liquiphant M with ECTFE coating, which

is installed in the standpipe, is used to measu-

re the density of the concentrate. Due to the

application conditions, measurement is subject

to pressure and temperature compensation. To-

gether with the Liquiphant FTL51 C, the density

computer FML61 issues the measured value on

a continuous basis.

Additional software modules, e.g. for deter-

mining reference density, for differentiating

between media and for detecting concentration

levels, provide assistance with quality control, for

example. A comparison with laboratory mea-

sured values produced satisfactory results. The

buildup of silicon at the fork must be counter-

acted by regular rinsing with caustic soda.

There are several advantages to performingdensity measurement using Liquiphant, including

product traceability and the minimization of

manual testing using hydrometers. Installing the

density measuring line not only saves time but

also money. In addition, there is no longer any

need to transport aggressive and toxic media,

which means reduced health risks for operators.

Liquiphant density, integrated into standpipe(DN 100 pipe)

To ensure the reliable operation of a measuring device, it is impor-

tant to select the correct one. The application conditions are the de-

termining factor when selecting a device. The two Endress+Hauser

selection tools for continuous level measurement and for level limit

detection in liquids and bulk solids will show you which device is

the right one for your application.

These selection tools include an overview of the measuring principles

together with technical data and the resulting benets of the device as well

as its application limits. Based on your application, we will recommend the

measurement method which, from our experience, is the most popular. The

objective of this selection tool is to come up with the best-priced solution

which is best suited to the application and tailored to the needs of the

particular application. In addition, you receive installation instructions for

the different technologies.

Application example: Level measurement in

aggressive media

When used in aggressive media, such as hydrochloric

acid, challenging demands are placed on the durabili-

ty of the installed measurement technology. An ideal

solution for the continuous recording of measured

values is the Micropilot M FMR45 (free space radar)

due to its diffusion-resistant PTFE full-body antenna.

This device version can be used in process tempera-

tures up to 00 C.

Order the following selection and planning tools at your

Endress+Hauser ofce

Continuous level measurement in liquids and bulk solids

(CP03F/00/en/07.09)

Level limit detection in liquids and bulk solids (CP007F/00/en/05.08)

Electromagnetic ow measurement usingPromag 50

Application experience: Liquiphant M used in regeneration plant

Selecting the correct

measuring principle


6/6

CM 019U/11/en/05.09

Straub/INDD .0

Endress+Hauser

Complete range of process

measurement technology

What's new

XXXXXXXXXXXXXXXXXX

Instruments International

Endress+Hauser

Instruments International AG

Kaegenstrasse

4153 Reinach

Switzerland

Tel. +41 61 715 81 00

Fax +41 61 715 5 00

http://www.endress.com

[email protected]

Publication details

Publisher: Endress+Hauser Messtechnik GmbH+Co. KG,D-79576 Weil am Rhein Project management and editorial team:

Jens Hundrieser, Daniela Storrer Design: Daniela Storrer Printing: Straub

Druck+Medien AG, 78713 SchrambergCirculation: ,000

The publisher is responsible for the content. Copies may be made only with

the publisher's permission.

Managing and organizing

information

Level measurement

ultrasonic | radar | guided radar | radiometric |

vibronic | paddle switch | level system | microwave

barrier | capacitance | conductive | hydrostatic

Pressure measurement

overpressure | absolute pressure| differential

pressure| ceramic| piezoresistive | CONTITE

Flow measurement

coriolis | vortex | electromagnetic | ultrasonic

time-of-ight| thermal mass | orice plates |

pitot tubes

Temperature measurement

resistance thermometers Pt100 |thermocouples TC | head, DIN rail,

eld transmitters | temperature switches

Liquid analysis

pH/ORP | conductivity| turbidity| solids content|

dissolved oxygen | hardness | chlorine |

ammonium | nitrate | phosphate | silicate | aluminum |

iron | chromate | copper | hydrazine | nitrite |

manganese | TOC | COD | BOD |

wastewater samplers | measuring stations

Registration

paper recorders | graphic display recorders

Systems and components

process display units | overvoltage protectors |

active barriers | Ex barriers | steam calculators |

energy managers | eld controllers |

limit switches

Endress+Hauser services

commissioning| calibration | maintenance

concepts | installed base audit| training|

inspection | hire

Endress+Hauser solutions

digital eldbuses | web-based asset management|

automation solutions | automation engineering

Fast access to online informationKnowledge is a key factor when it comes to increasing productivity and com-

petitiveness. With the W@M Portal, you always have the right information to

hand.

With W@M Life Cycle Management, Endress+Hauser provides an information

platform for management of your entire installed base and spare parts inventory

(including documentation), throughout the entire life cycle.

From engineering to procurement, commissioning, operation, maintenance

and the replacement of individual components, W@M provides up-to-date and

complete information, even on products from other instrumentation suppliers. Your

device data are available to you around the clock, and you save time when searching

for device information.

Service the key advantage

Did you know ...?

You can order all products, services, consumables

and spare parts around the clock in accordance with

your terms from the Endress+Hauser online shop.

You will find delivery times which are updated on a

daily basis and can check the delivery status of your

orders.

www.endress.com/shop

Another tool which is available to you on the inter-

net is a product data search engine which uses serial

numbers. By entering your serial number, specific

device details (order code details, production date,

product status, spare parts, technical information and

documentation) are displayed.

www.products.endress.com/device-viewer

More information can be found atwww.endress.com/lifecyclemanagement

With rising cost pressure and increased competi-

tion, the need for maximum exibility is great.

There is a noticeable trend towards the outsourc-

ing of industrial services.

Through systematic outsourcing of certain services,companies can focus better on their core competen-

cies. With Endress+Hauser's know-how, the produc-

tivity and performance of these companies can be

increased. Getting Endress+Hauser involved means

that you can avail of a wider range of opportunities

to optimize costs and processes. Our service has one

clear objective: To optimize your installed measuring

equipment with a view to maximizing efciency. In

addition, the range of services is being continuously

enhanced and adapted to new requirements and tech-

nical possibilities from commissioning and mainte-

nance to the smooth transition to new generations of

devices and software. Training courses, professionalcalibration services and maintenance strategies based

on practical experience are further important factors in

reducing costs.


www.endress.com/services

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Perspectives 15 Metal En