Emerson Fisher Control Disk Reference Manual

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Emerson’s Smart Wireless Technology Saves Plant €

¤160,000 Euros in Downtime and Maintenance

RESULTS

•Preventedproductionlossesof¤150,000Euros

•Reducedneedtoreplacepumpseverysixmonths

atacostof¤10,000Euros

APPLICATION

Gas-cleaningtowerwithafeedwaterinlet/outletsystem.

CUSTOMER

ChemicalplantinEurope.

Theplantproducestitaniumdioxidetoenhancethewhiteness,

brightness,opacity,anddurabilityofpaints,coatings,plastics,and

otherconsumerproducts.

CHALLENGE

Plantpersonneloperatedthegascleaningtowerwithanoverlldrain

thatonlydumpedwhenthevesselbecamefullofwaterandsand

settledtothebottom.Thewaterwouldbedisplaced,loseproper

dilution,andcleaningefciencywoulddrop,allowingunknownlevels

ofhydrochloricacidtobereleasedtotheatmosphere.Thesand

buildupwouldalsoerodeceramiccomponentsofthecirculating

pump,causinginternalleaksandcompletefailure.Bi-weekly

maintenancetocleanthevesselprovidedminimalimprovementto

cleaningefciency.And,theteamstillhadtoreplacethecirculating

pumpeverysixmonthstopreventaplantshutdown.Processshut

downforonedayforpumpreplacementisestimatedataproduction

lossof¤150,000Euros($194,000USD)and¤10,000Euros($12,886

USD)forpumpreplacement.

Emersonengineerslearnedaboutthegas-cleaningtowerchallenge

andrecommendedtheinstallationofanewdrainvalvewirelessly

controlledusingaSmartWirelesssolutionpoweredbyWirelessHART™

technology.

SOLUTION

Theapplicationrequiredtheinstallationofanewdrainvalveat

thebottomofthecleaningvesselsothatwaterandsandcouldbe

automatedtoushonanas-neededbasis.Todeterminewhenthe

vesselwasfullandreadytobedrained,aRosemount®2160Wireless

VibratingForkLiquidLevelSwitchdetectedwhenwaterlevelsreached

overllconditions.TheDeltaV™controlsystemwouldthensend

CHEMICAL

The first use of WirelessHART

devices has virtually eliminated

downtime in this process and

improved the efficiency of the

gas-cleaning tower.

D352095X012/MZ3(H:)/Jan14

CHEMICAL

awireless“open”commandtotheFisher®4320WirelessPosition

MonitorwithOn/OffOutputControlOptiontoopentheturndrain

valve.After30seconds,theDeltaVcontrolsystemwouldsendthe

“close”commandtocompletethedrainingcycle.

RESULT

ImplementedinDecember2011,theprojecthasproventobea

positivechangefortheplant.TherstuseofWirelessHARTdevices

hasvirtuallyeliminateddowntimeinthisprocessandimprovedthe

efciencyofthegas-cleaningtower.Theyexpecttogaintwofulldays

ofproductionperyearandavoidthecostofpumpreplacements.The

improvedperformanceofthecleaningtoweralsomeanstheplantisin

compliancewithlocalenvironmentalregulationandispreventingnes

andnegativepublicity.

Theplantstillcleansthevesselperiodically,butnoticedmuchlesssand

inthecleaningvessel,meaningmaintenanceworkersspendlesstime

inaconnedspaceexposedtochemicals.Workersafetyandworking

conditionshavebeenimprovedwiththewirelesssolution.

The Fisher 4320 Wireless Position Monitor with On/Off

Control Output and Rosemount 2160 Wireless Vibrating Fork

Liquid Level Switch were integrated into the DeltaV control

logic to provide traditional automation efficiency, but without

the traditional cost of engineering and installation of wired

instruments and final control elements.

Emerson Process Management

Marshalltown,Iowa50158USA

Sorocaba,18087Brazil

Chatham,KentME44QZUK

Dubai,UnitedArabEmirates

Singapore128461Singapore

www.Fisher.com

http://www.YouTube.com/user/FisherControlValve

http://www.Twitter.com/FisherValves

http://www.Facebook.com/FisherValves

http://www.LinkedIn.com/groups/Fisher-3941826

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Fisher,RosemountandDeltaVaremarksownedbyoneofthecompaniesintheEmersonProcessManagement

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Thecontentsofthispublicationarepresentedforinformationalpurposesonly,andwhileeveryefforthas

beenmadetoensuretheiraccuracytheyarenottobeconstruedaswarrantiesorguarantees,expressor

implied,regardingtheproductsorservicesdescribedhereinortheiruseorapplicability.Allsalesaregoverned

byourtermsandconditions,whichareavailableuponrequest.Wereservetherighttomodifyorimprovethe

designsorspecicationsofsuchproductsatanytimewithoutnotice.Responsibilityforproperselection,use,

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Click or scan the QR

code for information on

the Fisher 4320 Wireless

Position Monitor with

On/Off Control Output

Click or scan the QR

code for information

on the Rosemount2160

Wireless Vibrating Fork

Liquid Level Switch

Click or scan the QR

code for information

on the DeltaV

Control System