1.
Automating Truly Portable Skids
in a Hazardous Environment
Ray Emerson, Ph.D. – Project Engineer

2.
Presenters and Contributors
Ray Emerson, Ph.D.
Project Engineer
Christopher McLaughlin
Controls Engineer
Marc Goodwin
Engineering Manager

3.
Presentation Summary
What is a Portable Tank / Skid?
Process automation in hazardous environments
– Considerations and complications for portability
Case Studies
– Portable process units for use in both rated and general-duty
space
• Manual transfer of unrefined product between process areas
– Portable process units with semi-permanent process piping
• Transfer of unrefined product from different sources to a single
downstream unit, which may be in multiple locations
Business Opportunities and Savings
Summary and Additional Information

4.
What is a Portable Tank / Skid?
Image courtesy of
http://www.cutlooserv.com.au
Image courtesy of Image courtesy of
http://www.labconco.com http://www.schiercompany.com

5.
What is a Portable Tank / Skid?
Mobile vessel and
supporting equipment
Integrated control panel for
power distribution
Instrument signal wiring to
control panel
Communication to control
system
– Signal monitoring
– Batch control
– History collection
Image courtesy of
http://www.ipec-inc.com

6.
Presentation Summary
What is a Portable Tank / Skid?
Process automation in hazardous environments
– Considerations / complications for portability
Case Studies
– Portable process units for use in both rated and general-duty
space
• Manual transfer of unrefined product between process areas
– Portable process units with semi-permanent process piping
• Transfer of unrefined product from different sources to a single
downstream unit, which may be in multiple locations
Business Opportunities and Savings
Summary and Additional Information

7.
Hazardous Area Considerations
Control enclosures
– NEMA Type 7 XP
– Air / Nitrogen Purged
Power / Signal Wiring
– Explosion-proof (XP)
– Intrinsically Safe (IS)
• FISCO
– Non-Incendive (NI)
• FNICO
Communications
Image courtesy of http://www.control7.com
– Protocol
– Signal transmission

8.
Considerations and Complications for
Portability
Enclosures
– Explosion-Proof
• Heavy, big, expensive
• Difficult to integrate and / or
balance on a portable unit
frame
– Purged Enclosures
• Gas feeds to maintain positive
internal pressure / inert
environment
• Inhibits (but does not
necessarily prevent) portability
Image courtesy of http://www.oempanels.com

9.
Considerations and Complications for
Portability
Power / Signal Wiring
– Explosion-Proof
• Poured conduit seals to prevent
gas exchange
– Intrinsically Safe
• Signal barriers / isolators
• Segregation of I.S. and non-I.S.
wires
• Not all instruments are I.S.-
capable
Image courtesy of http://www.control7.com
– Non-Incendive
• Inhibits disconnection of signal /
power wires

10.
Considerations and Complications for
Portability
Communications
– Portability assumes use in multiple physical locations
– How to ensure the same instruments are the same DeltaV tags
everywhere?
?
Image courtesy of
http://www.labconco.com

11.
Considerations and Complications for
Portability
Communications Protocol
– FOUNDATION Fieldbus
• All locations must be on the same H1 port for IST/DST integrity
– Profibus DP
• All locations must be on the same segment for IST/DST integrity
– EthernetIP / Modbus TCP
• All locations must marshall (eventually) to a single switch for IST/DST
integrity
Signal transmission
– Ethernet (CAT-5E)
• Requires use of I.S. switches and wiring practices
– Fiber Optics
• Incapable of generating a spark!

12.
Presentation Summary
What is a Portable Tank / Skid?
Process automation in hazardous environments
– Considerations / complications for portability
Case Studies
– Portable process units for use in both rated and general-
duty space
• Manual transfer of unrefined product between process
areas
– Portable process units with semi-permanent process piping
• Transfer of unrefined product from different sources to a single
downstream unit, which may be in multiple locations
Business Opportunities and Savings
Summary and Additional Information

13.
Case Study 1 – Portable Product Transport
Design Requirements
– Portable vessel on 36”-wide frame
– 500L single-walled vessel on-board
– Control enclosure
• 304SS
• Weight limit <50kg to maintain skid balance
– Analytical Instrumentation + Agitator
• Controlled and historized in DeltaV
– Capable of communication in up to nine locations (General-
Duty and Class I Div I) throughout process facility

14.
Case Study 1 – Portable Product Transport
Design Solutions: Enclosure
– NEMA Type 4X, 304SS cabinet
– Main Power: Crouse-Hinds Ark-
Gard 2™ Series
• Interlocked Circuit-Breaking
Receptacles
• Twist-lock cannot turn until 3-prong Image courtesy of http://www.crouse-hinds.com
cord-cap is fully-inserted
• Quarter-turn twist-lock closes the
circuit and locks the cord cap
– Purge: Expo Mini-X-Purge System
• Continuous Flow-Through Purge Unit
– Serves as additional cooling for
components
• Pneumatic-electrical disconnect Image courtesy of
http://www.expoworldwide.com

15.
Case Study 1 – Portable Product Transport
Design Solutions: Signal
Wiring
– Use of MTL 5541 Repeater /
Power Supply
• 4-20mA signals, 2-wire, HART
Image courtesy of http://www.mtl-inst.com
– I/O connected to FESTO CPX
assembly with CPX-T05 bus
node
• Native Modbus TCP
• One assembly per skid with
unique IP address
– Maintains unique IST – DST
connection in DeltaV
Image courtesy of http://www.festo.com

16.
Case Study 1 – Portable Product Transport
Design Solutions: Communications
– Ethernet communications via:
• MTL I.S. Ethernet Isolators (9468-ET)
• MTL I.S. Switches (9466-ET)
• Mynah Virtual I/O Module (MIM-4201)
– Protocol: Modbus TCP
– Nine access points throughout process
facility
HAZARDOUS AREA NON-HAZARDOUS AREA
Images courtesy of http://www.mtl-inst.com

17.
Presentation Summary
What is a Portable Tank / Skid?
Process automation in hazardous environments
– Considerations / complications for portability
Case Studies
– Portable process units for use in both rated and general-duty
space
• Manual transfer of unrefined product between process areas
– Portable process units with semi-permanent process
piping
• Transfer of unrefined product from different sources to a
single downstream unit, which may be in multiple locations
Business Opportunities and Savings
Summary and Additional Information

18.
Case Study 2 – Multi-Stream Processing
Design Requirements
– Support 120+ instruments on a semi-portable skid in a ATEX
Category 2 (Class I Div I) space
• All process piping installed clamp-by-clamp to allow for
disconnection in 1mday
• All physical connections between the enclosure and control
network must be appropriately-rated for the space
– Utilize FOUNDATION Fieldbus and Profibus DP for all
signals to remain consistent with the General-Duty portions
of the facility

19.
Case Study 2 – Multi-Stream Processing
Design Solutions: Overall
– Application of ATEX Directive and Fieldbus Intrinsically Safe
Concept (FISCO) for all analog signals
• Power limitation in FOUNDATION Fieldbus segments
• All instruments ATEX-approved ( ) for Category 2
applications
– Discrete signals (solenoids, proximity switches, etc..)
communicated using FESTO CPX / MPA over Profibus DP
• Use of appropriate isolator / barrier, dependent upon the sensor
type
• Profibus DP to Fiber Optic Converter

20.
Case Study 2 – Multi-Stream Processing
Design Solutions: Enclosure
– NEMA Type 4X, 316SS cabinet
– Power Main: Power fed to
enclosure in unrated space
• Quick-disconnect wired to control
relay in rated-space enclosure
– Purge: Pepperl+Fuchs / Bebco
EPS Rapid-Exchange Y-Purge
• Automatic power-up after four air
exchanges
• Added control relay to enable
automatic power-off in the case of
enclosure pressure loss

21.
Case Study 2 – Multi-Stream Processing
Design Solutions: Signal Wiring
– FISCO Concept
• MTL 9122-IS Power Supply
– 265mA output Up to 16 I.S. Fieldbus
instruments
– Integrated, switch-selectable segment
terminator
Image courtesy of http://www.mtl-inst.com
• Relcom F251 I.S. MegaBlock
– Up to 8 instruments per H1 Fieldbus
port
Image courtesy of http://www.relcominc.com

22.
Case Study 2 – Multi-Stream Processing
Design Solutions: Signal Wiring
– Use of MTL Barriers / Isolators
• MTL5510 Discrete Input
• MTL7761AC Air Sensor
• MTL7060AC UV Sensor
Image courtesy of http://www.mtl-inst.com
– I/O connected to FESTO CPX
assembly with CPX-FB13 bus node
• Native Profibus DP
• One assembly per skid with unique
node address
– Maintains unique IST – DST
connection in DeltaV
Image courtesy of http://www.festo.com

23.
Case Study 2 – Multi-Stream Processing
Design Solutions: Communications
– Fiber Optic Communications:
• Hirschmann OZD PROFI 12M
– Profibus DP to Fiber Converter
– Protocol: Profibus DP
Fiber Optic Cable
Profibus DP
Image courtesy of http://www.belden.com Image courtesy of http://www.belden.com
HAZARDOUS AREA NON-HAZARDOUS AREA
Images courtesy of http://www.mtl-inst.com

24.
Presentation Summary
What is a Portable Tank / Skid?
Process automation in hazardous environments
– Considerations / complications for portability
Case Studies
– Portable process units for use in both rated and general-duty
space
• Manual transfer of unrefined product between process areas
– Portable process units with semi-permanent process piping
• Transfer of unrefined product from different sources to a single
downstream unit, which may be in multiple locations
Business Opportunities and Savings
Summary and Additional Information

25.
Business Opportunities and Savings
Decreased Capital / Operational Costs
– Use of unique units in multiple places
• Higher initial investment for specialized components
• Lower initial investment from building fewer process units
• Lower initial investment from qualifying fewer process units
• Lower operational investment, with fewer SOPs to write and
maintain
Increased Process Flexibility
– Safe implementation of units that may cross through multiple
area classifications within a single batch / campaign
– Ideal solution for small-scale facilities

26.
Presentation Summary
What is a Portable Tank / Skid?
Process automation in hazardous environments
– Considerations / complications for portability
Case Studies
– Portable process units for use in both rated and general-duty
space
• Manual transfer of unrefined product between process areas
– Portable process units with semi-permanent process piping
• Transfer of unrefined product from different sources to a single
downstream unit, which may be in multiple locations
Business Opportunities and Savings
Summary and Additional Information

27.
Summary
Take Home Message
– Portable Automation In Classified Areas Is Possible!!!
Portable automation in hazardous environments
– Key items to look for in your designs
• Enclosure
• Signal / Power Wiring
• Communications Protocol
– Two unique solutions for real-life design requirements
• Multiple new (and not so new) technologies and components
Use of standard DeltaV technologies to achieve:
– Tangible design, start-up, validation and process savings
– Increased flexibility in process operations

28.
Where To Get More Information
Presenter Contact Information
– Ray Emerson, Ph.D. – ray.emerson@newenglandcontrols.com
– Christopher McLaughlin – chris.mclaughlin@newenglandcontrols.com
– Marc Goodwin – marc.goodwin@newenglandcontrols.com
Electronic Sources
– http://www.newenglandcontrols.com
– http://www.mtl-inst.com
– http://www.pepperl-fuchs.com
– http://www.expoworldwide.com
– http://www.festo.com

29.
Questions