This presentation discusses automating portable process units in hazardous environments. It begins by defining portable tanks and skids before examining considerations for process automation in hazardous areas, such as enclosure types and wiring methods. Two case studies are presented: one for a portable product transport unit and one for a multi-stream processing unit. Both case studies discuss the design requirements and solutions implemented. The presentation concludes by discussing business opportunities and cost savings from portable automation, and provides contact information for presenters seeking more details.

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