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[ Star Enterprise of Chemical Machinery Equipment Network ] Cologne is a service provider of process measurement technology, which can provide flow measurement, level measurement, pressure measurement, temperature measurement, process analysis instrumentation and complete system solutions.
The group was founded in 1921 and is headquartered in Duisburg, Germany, with more than 3,700 employees on all continents.
Chemical machinery and equipment network star enterprise chemical machinery and equipmentThe group was founded in 1921 and is headquartered in Duisburg, Germany, with more than 3,700 employees on all continents.
BASF, one of the chemical giants, chose KROHNE's innovative Coriolis flowmeter technology as the core component of its safety instrumented system (SIS) at its factory in Freeport, Texas.
With its excellent cost performance, sophisticated structure, gas management system and on-site verification function; this new type of mass flow meter improves the reliability of the process and reduces the downtime of key process systems.
FlowmeterWith its excellent cost performance, sophisticated structure, gas management system and on-site verification function; this new type of mass flow meter improves the reliability of the process and reduces the downtime of key process systems.
Plant operators, looking for alternatives to aging equipment
The BASF plant in Freeport, Texas, produces super absorbent polymers (SAP), which can absorb and retain large amounts of liquid.
This water-absorbing polymer has a wide range of uses, from diapers, tapes, artificial snow, to hot and cold therapy kits, static water beds, and even aquatic toys.
This water-absorbing polymer has a wide range of uses, from diapers, tapes, artificial snow, to hot and cold therapy kits, static water beds, and even aquatic toys.
According to the introduction of Daniel Siddiqui, the electrical and instrument engineer of the factory, the factory needs to replace the flowmeter for the SIS system, which is a set of hardware and software control systems for key processes.
BASF is investigating the feasibility of upgrading to new technology while investigating the replacement of the original mass flowmeter.
BASF is investigating the feasibility of upgrading to new technology while investigating the replacement of the original mass flowmeter.
Siddiqui said: "The new solutions that BASF hopes to explore will not only maintain our high safety standards, but also save costs.
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The factory's SIS is required to meet the safety integrity level (SIL) 3.
The safety integrity level, defined in the IEC 61508 functional safety standard, is used to measure the performance of a system and the probability of failure of a safety instrumented function.
Among other things, SIL 3 requires SIS safety instruments to cover any abnormal conditions.
A redundant flow meter is required to alert the operator of any flow deviation and trigger a safety alarm.
Whenever the deviation is greater than 5%, the SIS system shuts down the production line.
The safety integrity level, defined in the IEC 61508 functional safety standard, is used to measure the performance of a system and the probability of failure of a safety instrumented function.
Among other things, SIL 3 requires SIS safety instruments to cover any abnormal conditions.
A redundant flow meter is required to alert the operator of any flow deviation and trigger a safety alarm.
Whenever the deviation is greater than 5%, the SIS system shuts down the production line.
The operator knows well-choosing the right instrument is essential to reduce downtime or false alarms.
In addition to the economic burden of production losses and material waste, temporary shutdowns under full load conditions—rather than planned normal shutdowns—may cause severe equipment wear.
In addition to the economic burden of production losses and material waste, temporary shutdowns under full load conditions—rather than planned normal shutdowns—may cause severe equipment wear.
Siddiqui commented: "We contacted Cologne, and the quote provided is significantly more cost-effective compared to other suppliers.
" In the BASF central laboratory in Germany, Cologne's instruments were tested and approved for use.
For SIS service.
" In the BASF central laboratory in Germany, Cologne's instruments were tested and approved for use.
For SIS service.
After considering various options, BASF finally chose two OPTIMASS 6400 Coriolis mass flow meters from Cologne to install them in series to create the required redundancy.
The caliber of the flowmeter ranges from DN 08 to 250, and the material can be stainless steel 316L, Hastelloy® C22 and UNS S31803 duplex steel.
The gauge installed by BASF is 2", the housing is made of 316 stainless steel, and the measuring tube is made of Hastelloy.
The gauge installed by BASF is 2", the housing is made of 316 stainless steel, and the measuring tube is made of Hastelloy.
The installation length of OPTIMASS 6400 meets the standards of the Process Industry Automation Technology User Association (NAMUR).
The process temperature is 400°C/752°F higher and -200°C/-328°F lower.
The process pressure is 200 bar/2900 psi higher.
It is equipped with a new generation of MFC 400 signal converter, which provides fast and comprehensive digital processing, as well as enhanced diagnosis and status indication functions.
converter The process temperature is 400°C/752°F higher and -200°C/-328°F lower.
The process pressure is 200 bar/2900 psi higher.
It is equipped with a new generation of MFC 400 signal converter, which provides fast and comprehensive digital processing, as well as enhanced diagnosis and status indication functions.
Cost-effective, and gas management system
After a comprehensive evaluation, plant operators believe that OPTIMASS 6400's cost performance and reliability are superior to other solutions.
If the reading obtained by the operator shows a deviation or other problems with a measured parameter, this instrument can help identify the problem in advance, and it can still operate reliably under abnormal working conditions.
If the reading obtained by the operator shows a deviation or other problems with a measured parameter, this instrument can help identify the problem in advance, and it can still operate reliably under abnormal working conditions.
In addition, OPTIMASS 6400 also has a key advantage-gas management.
Entrained gas will affect the sensitivity of liquid mass flow measurement, reduce the measurement accuracy, or even stop the measurement completely.
The new Coriolis mass flow meter technology ensures stable and uninterrupted measurement under high gas content conditions.
OPTIMASS 6400 detects two-phase flow by combining multiple measurements to provide a reliable indication of the gas content of the medium.
Even if the gas or air content varies from 0 to 100%, it still maintains continuous mass and density measurement, and always provides measured values.
At the same time, it can provide the status of two-phase flow, and output preset alarms in accordance with the requirements of NAMUR NE 107.
Entrained gas will affect the sensitivity of liquid mass flow measurement, reduce the measurement accuracy, or even stop the measurement completely.
The new Coriolis mass flow meter technology ensures stable and uninterrupted measurement under high gas content conditions.
OPTIMASS 6400 detects two-phase flow by combining multiple measurements to provide a reliable indication of the gas content of the medium.
Even if the gas or air content varies from 0 to 100%, it still maintains continuous mass and density measurement, and always provides measured values.
At the same time, it can provide the status of two-phase flow, and output preset alarms in accordance with the requirements of NAMUR NE 107.
The compact structure of this instrument brings another benefit-easy installation.
For example, OPTIMASS 6400 can adapt to this installation space without excessive adjustments to existing pipelines; other brands of meters require major renovations to the pipeline.
For example, OPTIMASS 6400 can adapt to this installation space without excessive adjustments to existing pipelines; other brands of meters require major renovations to the pipeline.
OPTIMASS 6400's proprietary vibration isolation system allows close installation spacing of meters, even flange butt installation.
Even for flange butt installation, its unique design can ensure that the vibration of the measuring tube has no effect on the performance of the instrument.
The meter has an oscillator, which causes the measuring tube to vibrate to produce fluid rotation, thereby generating mechanical distortion between the inlet and outlet of the measuring tube.
A sensor located upstream of the oscillator detects this vibration before the exit.
In other designs, the vibration of the measuring tube will be transmitted to the pipeline, which will cause errors if the meter is installed too closely.
Even for flange butt installation, its unique design can ensure that the vibration of the measuring tube has no effect on the performance of the instrument.
The meter has an oscillator, which causes the measuring tube to vibrate to produce fluid rotation, thereby generating mechanical distortion between the inlet and outlet of the measuring tube.
A sensor located upstream of the oscillator detects this vibration before the exit.
In other designs, the vibration of the measuring tube will be transmitted to the pipeline, which will cause errors if the meter is installed too closely.
Because the pressure loss of this flowmeter is lower; therefore, for the same pressure drop, BASF can choose a smaller caliber.
This is a real cost advantage for customers.
BASF also realized that another benefit is the optimization of stock spare parts.
All the instruments that arrive have the required gas management functions.
This is a real cost advantage for customers.
BASF also realized that another benefit is the optimization of stock spare parts.
All the instruments that arrive have the required gas management functions.
Daniel Siddiqui explained: "We have received strong support from Cologne and installed these two flowmeters within the budget.
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SIS meters must be calibrated regularly, and operators are required to establish verification test intervals.
With the OPTICHECK on-site verification tool, BASF can meet the requirements of a third party for independent verification of the instrument.
They are on-site, connecting online tools to collect measurement data to ensure that the accuracy of the flowmeter is better than the factory calibration of ±1%.
The benchmark data can be the historical maintenance data of the factory, or the field test results after a comprehensive inspection.
OPTICHECK also provides detailed reports, which are used as proof test documents for safety circuits.
With the OPTICHECK on-site verification tool, BASF can meet the requirements of a third party for independent verification of the instrument.
They are on-site, connecting online tools to collect measurement data to ensure that the accuracy of the flowmeter is better than the factory calibration of ±1%.
The benchmark data can be the historical maintenance data of the factory, or the field test results after a comprehensive inspection.
OPTICHECK also provides detailed reports, which are used as proof test documents for safety circuits.
The on-site inspection by operators can extend the operating time of the instrument; there is no need to remove the instrument from the pipeline, pack it, send it to a calibration organization, and then transport it back for installation.
The meter has been running well since the day it was started
In February 2020, plant operators began to use the new Coriolis meters for the SIS system.
According to Siddiqui, the system works well, provides accurate readings, and enhances confidence in SIS applications.
Siddiqui said: "By adopting Cologne's instruments, we uphold the safety of the system, and while getting free start-up support, we optimize cost efficiency.
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According to Siddiqui, the system works well, provides accurate readings, and enhances confidence in SIS applications.
Siddiqui said: "By adopting Cologne's instruments, we uphold the safety of the system, and while getting free start-up support, we optimize cost efficiency.
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Original Title: Application of KROHNE Coriolis Flowmeter in Safety System of BASF Chemical Plant
