PROTRAC Service Training - 2010-10-18 en

Field service training 18.
October 2010
Radiation-based process instrumentation
Agenda
Why nucleonic measurement? The nucleonic measuring principle Typical industries and markets Application examples Don't be afraid of gamma radiation PROTRAC: typically VEGA plics the idea with a future Configuration and parameter adjustment Source container shipping
Radiation-based process instrumentation Page 2 August 31, 2011 Roland Bonath
Reliable measurement technology for extreme process conditions

Why nucleonic measurement?
Suitable for extreme conditions Measuring principle works without contact to process medium High reliability of the measuring principle Some application areas still allow no other alternative to nucleonic measurement
The nucleonic measuring principle

A familiar measuring principle
The principle is based on the radiation emitted by radioactive isotopes Isotopes are mounted into a source holder The radiation is damped when penetrating material A detector mounted to the tank receives the radiation and converts it into an electrical signal The detector calculates the level, density or concentration of the measured product from the received (attenuated) radiation
Nucleonic measurement technology

Application areas
1
Level switching (1) Continuous level (2) Density and concentration as well as flow measurement of liquids (3) Interface measurement (4)
Typical industries and markets

Special application areas
Chemical industry Petrochemical industry Metal processing Oil and gas Pulp and paper Energy production Aggregates and mining Cement industry
Application example density

Flue gas desulfurization
Emission protection through flue gas desulfurization in coal power stations Lime milk suspension binds sulphur dioxide Concentration measurement of the lime milk by means of density measurement Lime milk is very abrasive
Application example density

Flue gas desulfurization
Emission protection through flue gas desulfurization in coal power stations Lime milk suspension binds sulphur dioxide Concentration measurement of the lime milk by means of density measurement Lime milk is very abrasive
Application example point level

Cellulose production
In cellulose production, wood chips are broken down chemically with the help of a cooking liquor In a special reactor, the cooking liquor is regenerated so that it can be used again Temperature 160 C, pressure 10 bar Aggressive process conditions The maximum level in the reactor must be monitored
Application example point level

Cellulose production
In cellulose production, wood chips are broken down chemically with the help of a cooking liquor In a special reactor, the cooking liquor is regenerated so that it can be used again Temperature 160 C, pressure 10 bar Aggressive process conditions The maximum level in the reactor must be monitored
Application example level

Polyester melt reactor
Its almost impossible to imagine our lives without polyester This versatile plastic is created in a polyester melt reactor Process temperature 220 C The vessel is enclosed in a heating jacket Rotation of the container Nucleonic measurement has proven itself worldwide in this application
Application example level

Polyester melt reactor
Its almost impossible to imagine our lives without polyester This versatile plastic is created in a polyester melt reactor Process temperature 220 C The vessel is enclosed in a heating jacket Rotation of the container Nucleonic measurement has proven itself worldwide in this application
Application examples point switch

Measurement in cyclones in cement applications
In the lower part of the cyclone, buildup often occurs which results in blockage To avoid downtimes, the cyclone must be monitored for buildup and possible clogging Compressed air can prevent clogging, however, over a longer period can damage the refractory lining The thickness of the buildup must be monitored, to activate removal with compressed air, if necessary
Radiation-based process instrumentation Page 13 31 August 2011 Roland Bonath
Application examples point switch

Measurement in cyclones in cement applications
In the lower part of the cyclone, buildup often occurs which results in blockage To avoid downtimes, the cyclone must be monitored for buildup and possible clogging Compressed air can prevent clogging, however, over a longer period can damage the refractory lining The thickness of the buildup must be monitored, to activate removal with compressed air, if necessary
Don't be afraid of gamma radiation

Highest sensitivity
Detectors of the PROTRAC series are extremely sensitive Conventional Geiger-Mueller counters do not even respond here Remarkable measuring precision and quick response times Advantage
Reduction of source activity
PROTRAC: typically VEGA!

A high degree of safety
Integrated safety functions Self monitoring and diagnosis Asset Management System Developed acc. to IEC 61508 Qualified up to SIL2 NEW
VEGA is the first supplier to offer level, point level and density instruments with SIL
plics The idea with a future

Simpler is better
plics makes everything simpler From selection to ordering to setup The modular system can be exactly adapted to the measuring task plics allows unrestricted selection and combination of sensors, process fitting, electronics and housings Advantage:
Simple planning, short delivery time, uncomplicated connection, fast setup and commissioning
plics Electronics
Anzeige- und Bedienmodul
4 20 mA HART Features
Profibus PA
Foundation Fieldbus
Relay output Analogue and digital inputs Serial multi-gauge communication bus Qualified up to SIL2 Simple electronics exchange
plics Housing
Aluminium
Stainless steel
plics Indicating and adjustment module
PLICSCOM
VEGACONNECT
Configuration and parameter adjustment

One module for all plics instruments
Simple adjustment via four compact membrane keys Measured value indication with unit Clear text with graphical elements Lighting (optional) Device information Diagnostics messages
PLICSCOM Easy and informative

Display
Measured value indication with unit Plain text with graphic elements Multilingual menu Lighting
Simple navigation
Clear menu structures Tree structures Unambiguous terms
plics Sensor system
NEW
PVT scintillator
Flexible plastic scintillator
NaI crystal
Source container VEGASOURCE
Design of the source container VEGASOURCE

Benchmarking data
Small space requirement and simple mounting Safe and easy source replacement Padlock for fixing the function settings Pneumatic switch-ON / switch-OFF Collimation angle 5, 20 and 40 Fire-proof version 821C / 30 min. (according ISO 7205, IEC 60405, AERB/SS/2, ANS N538)

Benchmarking data

Benchmarking data

Engineering design
Model A (Standard)
Figure: VEGASOURCE 35
Figure: VEGASOURCE 31

Benchmarking data
Weight with manual ON/OFF: SE31 app. 40 kg SE35 app. 87 kg Weight with pneumatic ON/OFF: SE31 app. 50 kg SE35 app. 97 kg Max. Cs-137 loading: SE31: 600 mCi /22,2 GBq SE35: 3.000 mCi / 111 GBq Max. Co-60 loading: SE31: 20 mCi / 740 MBq SE35: 100 mCi / 3,7 GBq Montingflange: DN100 PN16 Ambient temperature: -40 C ... +200 C

Altitude 12,500 m 5.0 8,848 m 1.0
Equivalent dose
The equivalent dose defines the energy dose taken in by the body through ionising radiation Measurement unit for the dose rate is the microsievert/hour (Sv/h) The sievert (Sv) unit is a measure of the biological effects of radiation The largest exposure results from a medical x-ray examination The dose rate a radiation source generates depends on the activity and the distance
Mount Everest
Scintillation detector
1.0
Zugspitze
2,962 m 0.1 0m 0.01 Dose rate in Sv/h
Venice
Mounting instructions
Mounting position for cont. level
The source container must be mounted at the height of, or slightly above, the max. level The radiation must be aligned exactly with the detector The source container and detector should be mounted as close as possible to the vessel to avoid control zones An gap between source container and vessel must be blocked off and marked. In general two or more source containers are used for large measuring ranges
Mounting position for point level
The source container version with an collimation angle = 5 is recommended for point level If larger collimation angle (20 or 40) are used, ensure that the ray is horizontal For this purpose, mount the radiation source container in such a way that the eyelet is positioned horizontally.
Mounting position for density
The most constant conditions for density measurement in pipes are achieved if the unit is mounted on vertical pipes If only horizontal pipes are accessible, the path of the ray should also be arranged horizontally to reduce the influence of air bubbles and build-up. In order to achieve a longer path of the radiation through the medium and thus a larger measuring effect
Pipe mounting bracket KV31
Figure: Pipe mounting bracket KV31 - vertical detector mounting

Figure: Pipe mounting bracket KV31 - horizontal detector mounting

Figure: 30 pipe mounting bracket KV31 with diagonal beam

Mounting accessoires
Figure: L-bracket PTB3 for FIBERTRAC and MINITRAC

Setup / Adjustment

Communication with all systems
PLS/SPS
Standard communication protocols are available for adjustment and connection in process automation
4 20 mA /HART Profibus PA and Foundation Fieldbus
VEGAMET
All settings can be made with one adjustment software (DTM or EDD) Simple setup is also possible via the indicating and adjustment unit PLICSCOM
AMS/ PDM DTM

EDD
EDD
Service and diagnosis Asset Management

Asset management functions
Failure Maintenance
Function control
Standardized status messages acc. to NE 107 or VDI/VDE 2650 Detailed diagnosis in the instrument with cleartext display Digital transmission via HART, Profibus and Foundation Fieldbus
Out of specification
Preventive maintenance
Early recognition of malfunctions Diagnosis evaluation with PACTware 4.0 Simplified servicing

Background calibration
80
The background calibration is necessary in order to register the natural background radiation The pulse rate of this background radiation is automatically subtracted from any other measured pulse rate

Full calibration
185
The radiation is switched on Most of the Gammaphotones will be blocked by the liquid The pulse rate is low Background pulse rate of the background radiation is automatically subtracted

Empty calibration
3891
The radiation is switched on Within the measuring range, the vessel is emptied as far as possible Ideally: 0%, maximum 40% Background pulse rate of the background radiation is automatically subtracted

Measuring mode
1941
The amount of pulse rate depends on the filling level An low number of pulses means an high filling level of the vessel The measured pulse rate is inverse proportional to the filling level An detailed relation between filling level and pulse rates is defined by the Linearization curve

Density measurement
For density and concentration measurements the MINITRAC needs the two parameters:
899
The absorption coefficient of the measured material The reference pulse rate Io
sample 1
For many applications an one-point calibration is sufficient This calibration point should be located as near as possible to the operating point If high accuracy is required over the complete measuring range two or more calibration points should be applied.
sample 1
DTM

Density measurement
The calibration points for an multiple point calibration should be located as far from each other as possible The calibration points should be uniformly distributed over the measuring range
1491
sample 2
sample 2
DTM

Density measurement
After the calibration points have been entered, the MINITRAC automatically calculates the linearization curve For recalibration (e.g. buildups in the pipe) the parameter real value correction can used The absorption coefficient is kept unchanged from the original calibration
1491
sample 1
sample 2
I = 10 * e - * roh * d

DTM Device Type Manager
Device DTM Driver for field devices and Remote I/O Communication DTM Driver for communication protocols such as Profibus, Foundation Fieldbus Provides all instrument-specific data and functions Runs in different frame applications such as PACTware, ABB, etc.
LIVE Demo

Electrical connection
Two connection chambers are available Depending on the instrument version the signal output is either in the primary or in the secondary chamber
Primary terminal connections
Secondary terminal connections


Primary terminal connections 1. 2. 3. 4. 5.
Primary terminal connections
Power supply Power supply 4 20 mA active output (only explosion protected devices) 4 20 mA passive output (only explosion protected devices) 4 20 mA input Switching input open collector Switching input relay contact Switching output (NPN transistor Multisensor communication bus 2x address switches for MGC
6. 7. 8. 9. 10.
Secondary terminal connections 1. 2. 3.

Secondary terminal connections
4 20 mA output option (IS safe devices) PLICSCOM connection Connections for external indication (VEGADIS) Ground connection
4.

Density calibration example
Density calibration One point calibration Min. process value: 1,5 kg/m Max. process value: 3,0 kg/m Pipe diameter 200 mm Pulse rate for density 3,0 kg/m: 1000 ct/s Pulse rate for density 1,0 kg/m: 3000 ct/s
Lesson:
Setup the gauge Build an linearization curve
Source container shipping

Source loading
Eckert & Ziegler load the VEGASOURCE container Eckert & Ziegler labels the type plate Eckert & Ziegler ship the source container direct to the end user
1. Serial number VEGASOURCE container 2. Order code 3. Document ID 4. Radiation angle 5. Local dose rate at a defined distance from the surface
6. Wording "Hochradioaktive Strahlenquelle" (highly radioactive source), depending on activity 7. Isotope (Cs-137 or Co-60) 8. Serial number of the source capsule 9. Source activity in Bq and mCi 10. Manufacturing date of the source capsule
Editorial
Field service training radiation-based process instrumentation Version: EN 18 October 2010
VEGA Grieshaber KG Am Hohenstein 113 77761 Schiltach Germany Phone +49 7836 50-0 Fax +49 7836 50-201 E-mail info@de.vega.com www.vega.com

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Field service training 18.

Radiation-based process instrumentation

Radiation-based process instrumentation Page 2 August 31, 2011 Roland Bonath

Reliable measurement technology for extreme process conditions

Radiation-based process instrumentation Page 3 August 31, 2011 Roland Bonath

The nucleonic measuring principle

Radiation-based process instrumentation Page 4 August 31, 2011 Roland Bonath

Nucleonic measurement technology

Radiation-based process instrumentation Page 5 August 31, 2011 Roland Bonath

Typical industries and markets

Radiation-based process instrumentation Page 6 August 31, 2011 Roland Bonath

Application example density

Radiation-based process instrumentation Page 7 August 31, 2011 Roland Bonath

Application example density

Radiation-based process instrumentation Page 8 August 31, 2011 Roland Bonath

Application example point level

Radiation-based process instrumentation Page 9 August 31, 2011 Roland Bonath

Application example point level

Radiation-based process instrumentation Page 10 August 31, 2011 Roland Bonath

Application example level

Radiation-based process instrumentation Page 11 August 31, 2011 Roland Bonath

Application example level

Radiation-based process instrumentation Page 12 August 31, 2011 Roland Bonath

Application examples point switch

Radiation-based process instrumentation Page 13 31 August 2011 Roland Bonath

Application examples point switch

Radiation-based process instrumentation Page 14 31 August 2011 Roland Bonath

Don't be afraid of gamma radiation

Radiation-based process instrumentation Page 15 August 31, 2011 Roland Bonath

PROTRAC: typically VEGA!

Radiation-based process instrumentation Page 16 August 31, 2011 Roland Bonath

plics The idea with a future

Radiation-based process instrumentation Page 17 August 31, 2011 Roland Bonath

Anzeige- und Bedienmodul

Radiation-based process instrumentation Page 18 August 31, 2011 Roland Bonath

Radiation-based process instrumentation Page 19 August 31, 2011 Roland Bonath

plics Indicating and adjustment module

Radiation-based process instrumentation Page 20 August 31, 2011 Roland Bonath

Configuration and parameter adjustment

Radiation-based process instrumentation Page 21 August 31, 2011 Roland Bonath

PLICSCOM Easy and informative

Radiation-based process instrumentation Page 22 August 31, 2011 Roland Bonath

plics Sensor system

Flexible plastic scintillator

Radiation-based process instrumentation Page 23 August 31, 2011 Roland Bonath

Source container VEGASOURCE

Radiation-based process instrumentation Page 24 31 August 2011 Roland Bonath

Design of the source container VEGASOURCE

Radiation-based process instrumentation Page 25 31 August 2011 Roland Bonath

Design of the source container VEGASOURCE

Radiation-based process instrumentation Page 26 31 August 2011 Roland Bonath

Design of the source container VEGASOURCE

Radiation-based process instrumentation Page 27 31 August 2011 Roland Bonath

Design of the source container VEGASOURCE

Design of the source container VEGASOURCE

Design of the source container VEGASOURCE

2,962 m 0.1 0m 0.01 Dose rate in Sv/h

Radiation-based process instrumentation Page 30 31 August 2011 Roland Bonath

Radiation-based process instrumentation Page 31 31 August 2011 Roland Bonath

Radiation-based process instrumentation Page 32 31 August 2011 Roland Bonath

Radiation-based process instrumentation Page 33 31 August 2011 Roland Bonath

Radiation-based process instrumentation Page 34 31 August 2011 Roland Bonath