Issue no.

15 Metal Industry

perspectives
2 3

Process solutions
Leakage monitoring online analysis Alarm function Online Analysis

Project expertise

One-stop shop for process automation and solutions

"Toughrequirementsandmaximumsafety arethedrivingforcesinourbusiness.
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 experience in the metal industry, and has a team of suitably qualified experts on hand to assist our customers. TheperspectiveseditorialteamspoketoJensHundrieser,Global IndustryManagerforMetalsandPrimaries,aboutEndress+ Hauser'smeasurementandautomationtechnologyandtrendsin themetalindustry. More than ever before, the economic situation is forcing companies in all industries to become more cost-conscious in terms of their production. What is Endress+Hauser's response to this? We identified this trend towards cost reductionsometimeago.Generally speaking,wetookalookatwhichcost reductionsolutionswecouldpropose toourcustomers,particularlyinthe areasofrawmaterialusage,process optimizationandenergyconsumption. Anexamplewouldbeateststationfor aircompressors,whichreducesmaintenancetimesanddowntime. Is it possible to discern any trends at the moment which are of relevance to measurement technology?
Jens Hundrieser, Global Industry Manager for Metals and Primaries at Endress+Hauser

Modernization of blast furnace stock line and profile level measurement Stock management

Reducing process costs

Memosens technology Unlocking the savings potential

Optimizing processes
Modernization of acid storage facility Density measurement Selection tools

Managing and organizing information

Fast access to information Service is the key advantage Did you know ...?

Robustandreliable
Safety coupled with intelligence Developedandmanufacturedinaccordancewith SIL/IEC61508(SafetyIntegrityLevel).The integratedHisto-ROM/M-DAT recordsandsavesthemostimportantprocessanddeviceparameters atalltimes.Usingtheceramicdifferentialpressuretransmitter,the smallestmeasuringrangesinthe Pascalrange(+/-0.5mbar)can bemeasuredaccuratelyandina reproduciblemanner(e.g.furnace pressureapplications). More information can be found at www.us.endress.com/pmp71 www.us.endress.com/pmd70 Temperature measurement without heat stress Resistancethermometersorthermocouplesmeasureprocesstemperatures,and theheadtransmittersfromtheiTemp TMT18xrangeensuresafeandaccurate transmission. Top-hat rails and field transmittersarealsoavailable. More information can be found at www.us.endress.com/temperature A fresh approach to measured value reliability The6GHZMicropilotMFMR44 processradardevicesareacost-effective alternativeforsmallermeasuringranges inbulksolidapplications.Theyareused in small silos that are filled to their maximumcapacity. Measuringrangeupto15minbulksolids Processtemperature-40Cto+80C FullyencapsulatedPTFEdiskantenna Variable process connection with slip-on flange ormountingclamp More information can be found at www.us.endress.com/fmr244

Yes, most definitely. Functional safety SIL/IEC61508(SafetyIntegrityLevel) isgrowinginimportanceinthearea ofmetalproduction.WearerespondingtothistrendwithSIL-approved measuringdevices,tailoredconsulting andtrainingcoursesallaboutSIL. Thisobviouslyincludesthedesignand documentationofsafetyfunctionsin chemicalplantsaswellasinfurnaces, burnerequipmentandalsogasholders (seeexamplebelow).Thesafetyof peopleandtheinstallationisofcourse ofvitalimportance.Leakagemonitoringincoolingcircuitsofelectricarch furnacesincreasethesafety At Endress+Hauser, marketing and sales are organized by industries. What does this mean? As"peopleforprocessautomation, wemustunderstandourcustomers andbeawareoftheirneeds.Ourteam ofindustrymanagersisalwaysonthe lookoutforpossibilities,marketshifts andtrends,inordertoguaranteethe successofourcustomersintothefuture.Theyareresponsibleforadopting andimplementingtherightstrategyfor eachindustry.Inaddition,wecultivate area-widenetworksforeachindustry,

togetherwithregionalandinternationalindustrymanagersandexternal industryrepresentatives. Environmental protection is also an important topic in the metal industry. Does measurement technology have a contribution to make here too? Environmentalprotectionisalwaysa topicofdiscussionwheneveremissionsaretobemonitoredorwherever processwaterandwastewaterarise. Itisinthisareainparticularthatour rangeofliquidanalysistechnologyis puttouse. Can customers continue to rely on Endress+Hauser after purchase? Inadditiontoproperplanning,keyfactorsinensuringthecontinuedsuccess ofthemeasurementprocessarecorrectcommissioningandmaintenance ofthesensors. Aswellashavingdetailedknowledge ofthesensors,Endress+Hauser's trainedservicetechniciansarefamiliar withtheparticularitiesoftheindustry andthedifferentapplicationsand willcarryouttheseandmanyother services.

ApplicationExample
Levelmeasurementatagasholder
Level measurement with non-contact radar and implementation of sensors in accordance with SIL Threeleveltransmittersareinstalledatagasometerwith a metallic floating cover which is held in place by several supportsarrangedaroundtheperimeter. ThethreeMicropilotsFMR30withaDN50hornare alsodistributedevenlyaroundtheperimeter.Thesignal is reflected onto the floating cover by metal surfaces whichareweldedontotheside.

Process solutions

Prosonic Flow inline ultrasonic flowmeters in cooling water circuits at DC electric arc furnaces

Alarm function silenced

Monitoring the flow rate of cooling water is a critical factor when it comes to safety. This has been acknowledged not just by the Norwegian autho rities. The requirements for flow monitoring have now become stricter. Elkem, a Norwegian company producing aluminum and metal, was consequently fitted out with new measurement technology. The key problem in cooling water circuits is the slow reaction time and the increase in temperature in the return line due to the low rate of flow. As a result, It is extremely difficult 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 field strengths present in the area surrounding the electric arc furnace. Endress+Hauser supplied several hundred Prosonic Flow 92F ultrasound flowmeters with PROFIBUS PA interface to Elkem. These are used in safety-critical applications for monitoring cooling water circuits in steel furnaces. If the flow rate in the return line falls below a certain level, an alarm is activated immediately. Thanks to PROFIBUS 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.

Leakage monitoring at the blast furnace using Promag electromagnetic flowmeters

Leakage monitoring
Even the smallest amount of water entering the furnace can have disastrous consequences. Flow and temperature measuring devices ensure prompt detection of leakages.
Integrated steel works have numerous safety-relevant water cooling circuits. These include, for example, 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 damage to 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 fire 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 imagine 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 flowmeter (Promag) is installed in both the supply and return lines of a tuyere, to enable continuous measurement of the cooling water flow rate. As soon as the flow rate differential exceeds 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 flow measurement, it is important to differentiate between DC and AC electric arc furnaces. For leakage detection purposes, electromagnetic flowmeters are used in all circuits in the case of AC furnaces, 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 "panels" are fitted out first. If the measurement results deviate from the defined limit values, the responsible positions are notified immediately.
 Endress+Hauser perspectives

A complete package for leakage detection Typically, electromagnetic flowmeters are used. The electronically remote version of these devices is selected in order to bypass ambient temperature effects. The temperature increase in the return line results in a change in density which is taken into account when measuring. This can be corrected using two temperature sensors which are mounted at a suitable point in the circuit. The accuracy of the flowmeters depends on the nominal diameter of the piping and the flow velocity. The deviations being detected must be within the range of measurement 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 flow rate for the supply and return lines. In the case of flow 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 sensors are connected to the PROFIBUS PA fieldbus. 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 maintenance and configuration 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 sufficient. The arrangement of the sensors is a key factor in securing a satisfactory result. Endress+Hauser supplies the complete package for leakage monitoring. It is ready to use and includes a PLC with programming 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.

CA71 analyzers used for cooling water

Increased plant availability thanks to online analysis

Buildup and corrosion are known to have a detrimental effect on pipes, cooling circuits and entire plants. By bearing this in mind and taking prompt action, plant availability can be increased significantly. 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-inducing 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 sufficiently up-to-date for the company, or process measurements were used which were not sufficiently accurate. That is why they switched to online analysis using 12 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.

Project expertise

Modernization of an old giant

Blast 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. Current 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 modernizing 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. 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 measuring 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 first 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 field devices including periphery (400 were implemented using PROFIBUS PA), as well as instrumentation engineering. The package also contained the supervision of mechanical and electrical works and training on site, the PROFIBUS configuration, platform test and support of the integration in Siemens PCS7 (PDM)

Blast furnace at ArcelorMittal Fos-sur-Mer

"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 Philippe 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 significantly 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 profit 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 behind their decision were obvious: Endress+Hauser's broad range of technical expertise, their flexibility 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 first one, with the same team and exactly the same project scope. This is testimony to the great partnership between ArcelorMittal and Endress+Hauser and proof that the best possible solution was delivered.

Using radar to measure stock line and profile levels in blast furnaces
Package solutions including engineering and commissioning
Blast furnaces must be fitted 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, profile recording is growing in importance. Stock line measurement: For charging purposes, it is essential that the axially symmetric bulk goods process be monitored when filling with a rotating chute and that positioning be controlled. Solution: Installation of three radar sensors in a radius, at 120 degrees intervals (three sectors in the blast furnace), as a replacement for mechanical sensors.
Depth measurement using radar sensor.

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.

Profile recording Using profile information to influence the bulk goods of material per defined ring segment (e.g. eleven rings) in the blast furnace.

Solution: Installation of five radar sensors at the furnace head, which measure the level along a radius. Using these data, the discharge profile can be roughly determined across five support points. While the accuracy is not as good compared to a conventional profile sensor, the advantages are as follows: Continuous measurement Profile information is Profile recording using always available No disruption to loading and radar sensors. 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.

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

Scope: ControlCare Field Controller SFC173 with local I/O modules SCADA software ControlCare P View FieldCare standard operating software (FDT-based tool for plant-based Asset Management) 100x Micropilot M FMR250
Endress+Hauser perspectives 

Reducing process costs

Memosens technology
Six-digitcostsavingsthankstodigitalpHsensor
pH measurement using the Liquisys M transmitter and a digital electrode with Memosens connection

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 fields and does not require field 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 finishing process at Salzgitter Flachstahl where it has proven itself capable of meeting all expectations, even in the toughest operating conditions. There'snomessingaroundwithsulfuric acid.ThisissomethingthatGerdReimann, operationsengineerinvolvedinsurface finishing at Salzgitter Flachstahl, is well awareof,asisHenningBorchers,manager ofinstrumentationandcontroltechnology fortheinternalserviceprovider. Themeasuringdevicesusedarepermanentlyexposedtoaggressiveenvironmental conditionsandarethereforeextremely vulnerable.Atleastthiswasthecasewith pHmeasuringpointsuptonow.Theyplay akeyroleintheproductqualityand,inthe past,wereastrainonthebudgetduetothe highcostsassociatedwiththeirpurchase, maintenanceandrepair. How things used to be TheoldmethodofpHmeasurementcomprisesacontainerwithasingleelectrode andareferenceelectrode,inadditiontoa diaphragm filled with a potassium chloride solution.Ontopofthecontainerisan amplifier with four contacts, which oxidize quicklyandmaycauseproblems.Inaddition,thesystemincorporatesaninternal temperaturesensor.Asthesystemuseddid notclosetightly,aggressiveliquidswhich sometimesdrippedontothehousing, slowlydestroyedconnections,cablesand electrodes. "Toguaranteecorrectmeasurement, someonehastoremovetheelectrodeon site,cleanit,immerseitinabuffersolution and calibrate the amplifier, explains Borchers.Thesameprocedureisthen repeatedwithbuffersolutionnumbertwo."

Inthepastthissometimestookonehourto do.(...)Whatappealedtomemostabout Memosenswastheencapsulatedelectrode. Youcanspillacidontheplastichousing withoutanycauseforconcern,saysReimannhappily. Is the changeover financially worthwhile? Althoughrelativelyhighcostsareincurred initially due to the modifications required tothepipework,thesearerapidlyabsorbed bythesavingsachieved.Ontheonehand, theE+Hsystemisalreadysubstantially cheapertobuy.Ontheotherhand,theoldstylepHmeasurementswerecostingusup to5,000Europerweekincludingmaterials andlabor.Thataddsupto100,000 Euro peryear,saysReimann.Itisnosurprise, therefore,thatinthelasttwoyearsSalzgitterFlachstahlhasgraduallyswitchedits plantovertoMemosens. Thesedays,Reimannkeepsonlythreeof thesenewsensorsinstockasspareparts. Incidentally,thereliabilityofMemosens meansthatplantavailabilityisincreasedandtheinternalserviceprovider's workload in the area of surface finishing is reducedtoaminimum.

Unbreakable technology According to Reimann, another key benefit ofMemosensisthattheelectrodedoes nothavetobecalibratedatthetransmitterwhereitisused:"Calibrationcan nowbecarriedoutatacentrallocation." Thismeansthatthereisnoneedtogo on site, which results in significant cost andtimesavings.Furthermore,anywork processesthatcantakeplaceoutsidethe plantenhanceworkplacesafety,Reimann explains.ThisiswhySalzgitterFlachstahl haspurchasedaslimmed-downtransmitterspeciallyforthelaboratoryonwhicha laboratorytechniciancannowcalibratethe electrodesinpassing.This takes just 20 minutes per electrode. Wehavebeenlookingforalternatives foralongtimenow,andhavereallytried everythinginthelast0years.Butthere was nothing else. The breakthrough finally camewhenwetriedMemosensfrom Endress+Hauser,Reimannpointsout. More information at www.us.endress.com/ memosens

Unlocking the savings potential

More efficient usage of raw materials and energy or a reduction in emissions - there are great savings to be made through investmentinadaptedautomationsolutions
In the different industrial segments of the iron and non-iron industries, savings trends can be identified in two main segments: utilities or auxiliary circuits with steam, compressed air, natural gas, water and electricity; and industrial gases such as N2, O2, H2, argon and CO2. Example of savings: argon dosage Oneofseveralpracticalexamplesofhowtoreducecosts andachievesavingsisbottomblowingofargon/nitrogen coupled with mass flow and pressure monitoring, as for example in steel works. In this field of application, highly accurate mass flow measurements are achieved with the help of Coriolis flowmeters combined with pressure sensors and a fieldbus system such as PROFIBUS PA.The replacementofconventionalpitottubesresultedinsavings ingasconsumption,asgreateraccuracyresultedinbetter processcontrolthroughthesmallermeasurementwindow. Insteadofatleast1%ofthemeasuredvalueplusconversionerrorandcreepinglossesinconventionalmeasurement,0.35%ofthe(current)measuredvalue(mass)is nowachieved.Forthisreason,dosingisnowmuchmore precise, resulting in cost savings of a five digit number Eurorange. Example of savings: compressed air leak detection Compressedairnetworksareanotherstartingpointfor achievingcostsavings.Inasteelworksplant,approximatelyeightpercentoftheenergyrequirementsarefor compressedair.Togenerate1kWhofcompressedair, approx.7kWhofelectricityarerequired.Theindustrial costofcompressedairisapprox.0.75EuroperkWh.With leakagelossesofupto30percent,thisisanareawith massive savings potential, which can be fulfilled through processautomation. Measure first, then improve The way to approach any kind of optimization is firstly to obtaintransparencywithregardtotheprocessesaffected. Forthisreason,itisessentialthatdatabecollectedatclose intervalsandsubsequentlyanalyzed.Greatestsavings potential can be identified on this basis. With the preconditionsofthetransparencyoftheenergyconsumption andtheraisedawarenessoftheemployeesexperiencehas shownthatanEnergyMonitoringSystemsaves5to15 percentoftheannualenergycosts.Asaninitialapproximation,8percentappearstobeareasonableestimate Saving energy with Endress+Hauser Duetoincreasingenergycosts,bothcustomersand suppliers have an interest in verifiable and accurate energybalancingandinvoicing. Endress+Hauserprovidesthefollowing servicesinprocessandauxiliarycircuits: Energymonitoring Leakagemonitoringofsteam,compressedair Consumptionmonitoringofargon, steam,compressedair,N Efficiencydetermination: steamboilers,heatexchangers Forenergymeasurementinutilities,a solutionisprovidedwhichcanbecalibrated and verified on site. This includes suitable measurementtechnology,totalaccuracy calculation and verification.

In this application, highly accurate mass flowmeters in accordance with the Coriolis principle are used together with pressure sensors devices with digital communication in PROFIBUS PA ensure the highest level of accuracy.

4Endress+Hauserperspectives

Process optimization

Operational experience
Fromthemodernizationofanacidstoragefacility inthecoldrollingmill(CRM)atArcelorMittal.
Micropilot FMR245 level transmitter Electromagnetic flow measurement using Promag 50

A holdup in the pickling process could result in a production stoppage across the entire cold rolling mill. This was a risk that ArcelorMittal Eisenhttenstadt GmbH was by no means willing to take. For this reason, the acid storage facility in the regeneration area was upgraded to ensure the continuous supply of pickling line. Toensuretrouble-free,continuousoperation,itisofvital importancethatfaultsarediagnosedquicklyandreaction timesreduced.Inordertoachievethisobjective,theupgradefocussedontwoaspects.Ontheonehand,acentral visualizationsystemfortheproductionprocesswastobe setupintheregenerationswitchroomtoallowforbetter observationandmonitoring,includingtrackingofquantitiesandlevels.Ontheotherhand,therapidprocurement ofsparepartswastobeguaranteed,inordertoensure maximumplantavailability. Technology at work for ArcelorMittal Intelligent field devices form the basis for optimum process controlcoupledwithamodernmaintenanceandrepair

strategy.Inthisproject,radarmeasuringdevices(type FMR45)andvibrationlimitswitches(typeLiquiphant FTL51)wereusedforlevelmeasurement.Electromagnetic flowmeters (type Promag 50P and W) were used, as were vortexmeters(Prowirl7)forcompressedairmeasurement.Pressuremeasuringinstruments(CerabarM)and Pt100resistancethermometersTR13werealsoused. ThePROFIBUSPAsystemisconnectedviaaPROFIBUS DPcardtoaSiemensS7controller.TheWonderware Intouchsystemisusedasthehumanmachineinterface. BasedontheFDT/DTMstandard,nonproprietary,open configuration and diagnostic tools are being used to an increasingextentformeasurementandcontroltechnology. ArcelorMittalusesFieldCarefromEndress+Hauserboth forcommissioningandasaservicetool.Whendiagnosing errors, several defined error messages now accumulate in thevisualizationsystem.Duetothedifferentiationofoperationalrequirementsformaintenanceandrepairservices, itispossibletodecideusingsensordiagnosticinformation whetheraproblemrelatestoameasurementtechnology deviceorafaultintheprocess.

"W@M always provides reliable information Fromengineeringtoprocurement,commissioning,operation,maintenanceandthereplacementofindividualcomponents,theW@M-Portal(Web-EnabledAssetManagement) providesup-to-dateandcompleteinformation.Inthecase ofEndress+Hauserdevices,technicaldata,documentation, productstatus,sparepartslistsandeventsfromthelife cyclearemadeavailableautomatically. In conjunction with a classification of critical measuring pointsandthemaintenanceriskinvolved,recommendationsaremaderegardingsparepartsprocurement.Theresultisguaranteedplantavailability,streamlinedspareparts management and an associated reduction in fixed capital. TheW@M-Portaldisplaysallthedataviaastandard browser,therebyeliminatingtheneedtoinstallandmaintainadditionalsoftware. Thismeansthatcustomerscanhaveround-the-clock accesstoplant-relatedinformationfromanyinternet-compatiblePC.

Density measurement in a spray roaster

Applicationexperience:LiquiphantMusedinregenerationplant
To optimize the roasting process in the regeneration, density measurement is used to determine density in the more highly concentrated utilized acid. The measurement 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 overconcentrated and crystallizing. Themediumtobemeasuredisahighlycorrosivemixtureofhydrochloricacid(0%-33%), iron(II)chloride,ironchloride,ironoxideand siliconoxide,andplacesenormousdemandson themeasurementtechnology.Thedensityvaries from 0.95 g/cm to 1.5 g/cm, the process temperaturerunsbetween9and95C,andthe pressure range varies from 0 to 5 bar. The flow velocityism/s. The objective was to find a reliable and accurate wayofmeasuringdensitywithaviewtoreplacingthetwomanualmeasurementstakendaily inalaboratory.Ofparticularimportancewasa highdegreeofreproducibility,withmeasured valuescomparabletothelaboratoryvalues,if possible. TheLiquiphantMwithECTFEcoating,which isinstalledinthestandpipe,isusedtomeasurethedensityoftheconcentrate.Duetothe applicationconditions,measurementissubject
Liquiphant density, integrated into standpipe (DN 100 pipe)

Selecting the correct measuring principle

To ensure the reliable operation of a measuring device, it is important to select the correct one. The application conditions are the determining 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. Theseselectiontoolsincludeanoverviewofthemeasuringprinciples together with technical data and the resulting benefits of the device as well asitsapplicationlimits.Basedonyourapplication,wewillrecommendthe measurementmethodwhich,fromourexperience,isthemostpopular.The objectiveofthisselectiontoolistocomeupwiththebest-pricedsolution whichisbestsuitedtotheapplicationandtailoredtotheneedsofthe particularapplication.Inaddition,youreceiveinstallationinstructionsfor thedifferenttechnologies. Application example: Level measurement in aggressive media Whenusedinaggressivemedia,suchashydrochloric acid,challengingdemandsareplacedonthedurabilityoftheinstalledmeasurementtechnology.Anideal solutionforthecontinuousrecordingofmeasured valuesistheMicropilotMFMR45(freespaceradar) duetoitsdiffusion-resistantPTFEfull-bodyantenna. Thisdeviceversioncanbeusedinprocesstemperaturesupto00C. Order the following selection and planning tools at your Endress+Hauser office Continuouslevelmeasurementinliquidsandbulksolids (CP03F/00/en/07.09) Levellimitdetectioninliquidsandbulksolids(CP007F/00/en/05.08)
Endress+Hauserperspectives5

topressureandtemperaturecompensation.TogetherwiththeLiquiphantFTL51C,thedensity computerFML61issuesthemeasuredvalueon acontinuousbasis. Additionalsoftwaremodules,e.g.fordeterminingreferencedensity,fordifferentiating betweenmediaandfordetectingconcentration levels,provideassistancewithqualitycontrol,for example.Acomparisonwithlaboratorymeasuredvaluesproducedsatisfactoryresults.The buildupofsiliconattheforkmustbecounteractedbyregularrinsingwithcausticsoda. Thereareseveraladvantagestoperforming densitymeasurementusingLiquiphant,including producttraceabilityandtheminimizationof manualtestingusinghydrometers.Installingthe densitymeasuringlinenotonlysavestimebut alsomoney.Inaddition,thereisnolongerany needtotransportaggressiveandtoxicmedia, whichmeansreducedhealthrisksforoperators.

Managing What's new and organizing XXXXXXXXXXXXXXXXXX information

Endress+Hauser Complete range of process measurement technology

Level measurement

Fast access to online information

Knowledge 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. More information can be found at www.endress.com/lifecyclemanagement

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-flight| thermal mass | orifice plates | pitot tubes

Temperature measurement
resistance thermometers Pt100 | thermocouples TC | head, DIN rail, field transmitters | temperature switches

Liquid analysis

Service the key advantage

With rising cost pressure and increased competition, the need for maximum flexibility is great. There is a noticeable trend towards the outsourcing of industrial services. Through systematic outsourcing of certain services, companies can focus better on their core competencies. With Endress+Hauser's know-how, the productivity 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 efficiency. In addition, the range of services is being continuously enhanced and adapted to new requirements and technical possibilities from commissioning and maintenance to the smooth transition to new generations of devices and software. Training courses, professional calibration services and maintenance strategies based on practical experience are further important factors in reducing costs. More information can be found at www.endress.com/services

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 | field controllers | limit switches

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 internet 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

Endress+Hauser services
commissioning | calibration | maintenance concepts | installed base audit | training | inspection | hire

Endress+Hauser solutions
digital fieldbuses | web-based asset management | automation solutions | automation engineering

Instruments International Endress+Hauser Instruments International AG Kaegenstrasse 2 4153 Reinach Switzerland Tel. +41 61 715 81 00 Fax +41 61 715 25 00 http://www.endress.com info@ii.endress.com 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 Schramberg Circulation: 2,000 The publisher is responsible for the content. Copies may be made only with the publisher's permission.

CM 019U/11/en/05.09 Straub/INDD 2.0