Rugged instrumentation for reliable measurement and control

Applications By Industry

There are many applications where the process alarm trip is critical. In these cases, if the process equipment is not brought to a safe condition it can cause expensive maintenance, production loss, or environmental impact. The commercial impact is enough that the cost of a second or redundant trip source is negligible.

Reasons for redundant alarm trips:

  • Loss of flow requires that a pump be shut down to protect it
  • If final pH correction is out of specification, you need to divert the effluent
  • High vibration on a large motor or pump mandates a shutdown
  • A high rate of change in reactor temperature requires a shutdown
  • High pressure at a spec break needs the source shutoff

Redundant Trips Sources
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If a PLC or other BPCS is available, it commonly provides only one trip execution. Adding a stand-alone process trip to the loop provides a redundant trip source, preventing common mode failure. Moore Industries’ SPA2 model is a high volume choice for this trip.

When a BPCS is not available, stand-alone alarm trips such as the SPA2, can take on the task. Hard alarm trips complement a PLC by providing redundancy, simple control, and critical safeguarding. Hard alarms are not exposed to adverse effects of common-mode failure because they maintain complete independence from the PLC or DCS.

Key attributes:

  • Accept a signal input from transmitters, temperature sensors and a wide array of other monitoring and control instruments
  • Dual and quad alarm trip outputs
  • Site- and PC-programmable

Check out the SPA2 datasheet and Moore Industries Online catalog for more information.

There are several reasons why users want two HART to MODBUS converters on one HART network that has up to 16 transmitters.

Fortunately, HART protocol supports two masters; one must be declared the Primary Master and the other is assigned the Secondary Master role. The HES HART to Ethernet Gateway System and HCS HART Concentrator System HART-to-MODBUS RTU Converter both have configurable Primary and Secondary Master settings. That simply means that they communicate to HART devices in different polling intervals.

Dual HART to Modbus conversion

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The HES has an Ethernet back-end using MODBUS/TCP protocol. The HCS outputs RS-485 serial with MODBUS RTU.  One HART network could have two HCS, two HES, or one of each model.

  • When you have two MODBUS Hosts with serial communications and each requires process variable and diagnostic data from all transmitters, you need two HCS units.
  • As shown above, if you have two MODBUS masters with one being serial and the other being Ethernet, you would need one each of the HES and HCS.
  • On critical networks, some users will have two converters for redundancy purposes. In this case, you could employ two HCS, two HES or one of each.

Key attributes:

  • Both HES and HCS are HART and MODBUS devices
  • Both capable to operate as HART Primary Master or Secondary master
  • Choose from Serial or Ethernet connectivity

Check out the HES datasheet and Moore Industries Online catalog for more information and the HCS datasheet and online catalog page.

Excessive vibration in a motor/pump is symptomatic of a problem that can cause further damage or deterioration. If ignored, the results are higher maintenance and downtime. In some situations, it could also lead to safety concerns.

Large Motor Pump Vibration Trips
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Vibration sensors or accelerometers can be installed to detect abnormal vibration levels. Alarm trips can monitor the vibration sensors and provide a local trip source for the motor. These pumps can be installed in many different environments so Class I, Div 2 certification and wide ambient temperature specs for these alarm trips are key characteristics.

If necessary, the vibration levels can also be retransmitted back to the control system using the Analog Output signals from the alarm trips.

Shown in the diagram above is the STA Functional Safety Limit Alarm Trip logic solver which is IEC61508 certified. If the loop isn’t part of a safety instrumented system where a standard alarm trip will do, then the SPA2 Programmable Limit Alarm Trip would be a great alarm trip choice.

Key attributes:

  • Capable of monitoring vibration sensors
  • Exida approved for use in a Safety Instrumented System
  • Up to SIL 3 Capable

Virtually every facility has some number of old legacy signals that must be converted to something more useable, such as 4-20mA. The best way to convert those signals is with a programmable isolator that outputs clean, stable signals and has the flexibility to be applied to a variety of conversion needs.

SIY Signal Conversion
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Such an isolator is the highly flexible SIY PC Programmable Signal Isolator and Converter. This exceptional signal converter is PC-configurable, making it easy to change the signal conversion parameters as the needs change. Whether the input is a voltage between -0.5V to 11V with the minimum span being 250mV within that overall range, or current between -2.5mA and 55mA with the minimum span being 1mA, because the SIY isolator is output loop powered the output will always be some form of 4-20mA. However, the flexible SIY allows configuration of that 4-20mA output to meet specific requirements, such as setting the lower range limit of the output to be between 3.8mA and 17.4mA and the upper range limit to be between 7.8 and 21.4mA. If even more flexibility is needed, the SIY includes an 85-point linearizer that can be used to characterize the input to output relationship.

Key attributes:

  • Isolation: 1500Vrms field-mount / 500Vrms DIN-mount
  • Temperature Specs: -40°C to 85°C / -40°F to 185°F
  • Drive Capacity: 654Ω @ 24Vdc
  • RFI Rejection: Up to 20 V/m with <0.1% span error
  • 85 Point Linearization
  • Output Damping

Just about every facility has the need for a simple fast solution. If you have a Moore Industries SPA2 Programmable Limit Alarm Trip with Current and Voltage input, 4 Alarm Relays, and an Analog Output on your shelf, it can be an instrumentation solution waiting for a problem. The SPA2, with easy-to-configure operating parameters, is site-programmable using front panel pushbuttons and PC-programmable with Moore Industries’ free Intelligent PC Configuration software.

Simple Ad Hoc Alarming
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The versatile SPA2 Programmable Limit Alarm Trips provides on/off control, warns of unwanted process conditions, and provides emergency shutdown. In this application, the SPA2 is placed in an R-BOX enclosure that is NEMA 4X and is designed to meet standards for enclosing indoor and outdoor electronic instruments approved for use in Class I, Div 2 / Zone 2 locations.

Key Attributes of the SPA2 Programmable Limit Alarm Trips:

  • Four levels of alarm warning or shutdown
  • On / Off control
  • Loop power supply: 24V @ 25mA
  • Loop Display: full 5 digits + 5 alphas for Engineering Units on the display
  • Signal splitter: Measure a 4-20mA, isolate it and retransmit it to a secondary system
  • Linearizer: characterize the input/output relationship with a 128-point linearizer

SPA2 Signal Conversion key attributes:

  • Input: 0-11V with a minimum span of 250mV
  • Input: 0-50mA with a minimum span of 1mA
  • Output: 0-10V with a minimum span of 250mV
  • Output: 0-20mA with a minimum span of 1mA

The SPA2 software is downloadable for free. Click here for software and more information on the SPA2 or the R-BOX enclosure.

It is common practice to wire data acquisition thermocouples all the way to the DCS using thermocouple extension wire. Over time, extension wire corrodes and becomes contaminated causing unacceptable measurement errors. When that occurs, the two choices are to replace the same wire and perpetuate the problem, or change to a different technology.

Remote I/O is a valid cost balance between individual temperature transmitters and direct wiring thermocouples. It also eliminates thermocouple extension wire as an error source. Remote I/O has the same measuring circuit as a temperature transmitter, but the back-end communication is both MODBUS RTU and MODBUS /TCP.

Remote IO Replaces Thermocouple Extension Wire
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When using MODBUS, if fiber optic communications or radios are desired, those options are available, and if all your data acquisition points came into the DCS as MODBUS, existing analog input cards can be eliminated or repurposed. Other advantages with MODBUS are that each input and output is isolated in all directions so there is never a ground loop, and each input and output has its own chip, so the loss of a processor would only cause the loss of one point.

The I/O hardware used in this application is the NET Concentrator System® (NCS) which is Class I, Div 2 certified and can tolerate ambient temperatures from -40 to +85°C. It provides a real-time signal gateway between the field and your control strategy, eliminating the constant degradation of thermocouple measurement accuracy caused by the thermocouple extension wire. Copper wire and an all digital measurement and delivery system assure the measurement is as accurate as the sensor.

Key Attributes for the NCS:

  • Superior 20-bit input and 18-bit output resolution
  • Installs in harsh ambient temperature conditions,-40°F to 185°F
  • Class 1, Div 2 Non-Incendive Quick and simple programming
  • Isolation and RFI/EMI protection
  • Peer-to-Host and Peer-to-Peer operation
  • Transmit any distance, over any terrain
  • Data logging capabilities

Check out more on the NET Concentrator System® (NCS) or on Moore Industries’ custom Instrument Panels and Systems from our catalog that are turnkey solutions for your process, automation, Safety Instrumented System (SIS) monitoring, and control needs.

Download the  Instrument Panels and Systems line card PDF to learn more about high-density panels, field-mounted cabinets,  control room cabinets, pneumatic Instrument Interfaces panels, components and more.

It is common knowledge that pulling new wires from the field back to the control system is very expensive especially when they transverse a hazardous area. Next time the need arises use alternate technology to avoid such costs.

Avoid Pulling New Wires

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The NET Concentrator System (NCS) family of Remote I/O hardware can easily be configured by the user to operate in what is called Peer-to-Peer mode. This means the modules in the field take the analog and discrete signals, digitizes them for transportation over a single physical layer, moves them to the control room and recreates the signals back to analog and discrete signals. To the PLC, this connection method appears the same as copper wires do. The 4-20mA signal comes in on one side and out as 4-20mA on the other side. Thermocouples and RTDs come in on one side and out on the other side as 4-20mA. Discretes come in and go out as contact closures. Communications is bidirectional so signals can come in and out on both sides.

Shown in the sketch is communications via fiber optic cable. This requires RS-485 to fiber converters on each end. In most applications the user finds one pair twisted shielded copper wire for simple RS-485 communication between the field and control room. Redundant communications is also a standard feature that can be implemented with the NCS.

All configuration is accomplished without needing to be a PLC programmer. The NCS includes a Web server utility that allows configuration and real time viewing of process data via Internet Explorer Web browser over your Intranet (or Internet) from any PC, with proper security password clearance.  Alternatively, our free Intelligent PC configuration software, NCS Config, can also be used for programming and viewing of real time process data via the Ethernet port.

Key attributes:

  • All input types from 4-20mA to discrete
  • Class I, Div 2 Zone 2
  • Ambient operating temperature range from -40 to +185°F
  • Easy programming on a PC over the network from the NCS built-in web browser

Check out the datasheet and Moore Industries Online catalog for more information.

It was common practice to wire data acquisition thermocouples all the way back to the DCS using thermocouple extension wire. Over time the extension wire corrodes and becomes contaminated causing unacceptable measurement errors. When that occurs in facilities still using this wiring method, the choices are to replace in kind and perpetuate the problem or change to a different technology.

High Density Temperature MultiplexerDownload the PDF file

A common alternate technology is to mount multichannel temperature modules close to the thermocouples. There is a short thermocouple extension wire run between the thermocouple and the temperature module, but because it is short it is manageable over time. The output side of the temperature module uses copper wire back to the DCS and copper wire usually lasts the life of the installation. The output of our modules is typically RS-485 with a Modbus RTU multidropped network, so we consume very little of the copper wire between the processing unit and the DCS.

The TCM Temperature Control Module is a 16-channel temperature multiplexer that accepts any sensors. The TCM is Div 2 and IS certified and can tolerate ambient temperatures from -40 to +85°C.  The TCM is a loop-powered, multipoint, HART temperature transmitter. 

If MODBUS RTU is your preferred communication protocol, the HMC HART  to MODBUS Converter converts the TCM HART output to MODBUS RTU. The HMC can read 32 temperatures in ~2 seconds and deliver to your DCS using RS-485.

This high density temperature multiplexer solution eliminates the constant degradation of thermocouple measurement accuracy caused by the thermocouple extension wire. Copper wire and an all digital measurement and delivery system assures the measurement is as accurate as the sensor.

Key Attributes

  • TCM is a 16-point HART temperature transmitter
  • TCM is Div 2, IS certified, and can tolerate ambient temperatures from -40 to + 85°C
  • HART to MODBUS conversion with the HCM

Check out the datasheet and Moore Industries Online catalog for more information.

DCS and other BPCS offer HART input cards, but not all those cards support HART Multidrop functionality. Yet multidrop may well be ideal for the infrastructure available.

BPCS does not support HART multidrop
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The Model HES can bridge that technology gap perfectly. As a HART master, the HES supports one or four HART networks. Each network can have as many as 16 transmitters. Assuming the transmitters support Command 9 that is 8 variables we retrieve from each device. 8 variables x 16 transmitters x four networks = 512 variables sitting in Modbus registers waiting for the request from the Modbus/TCP host.

Additionally, the Model HES can retrieve as many as 25 diagnostic bytes with Command 48 from each of the 64 transmitters.

Key Attributes:

  • Gets more process data to BPCS with limited input card capability
  • Delivers valuable diagnostic data to enable preventive maintenance
  • Keeping the signal digital increases accuracy and saves money

There are different technologies available to eliminate long homeruns of thermocouple extension wire and the associate error caused by the wire. A popular choice is to DIN-rail mount HART temperature transmitters in the field and then bring the copper wire back to the DCS input cards.

Add HES to Remote DIN
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By today’s standards there is no need to have these data acquisition points consume all those DCS analog input cards. It is quite simple to convert these temperatures to MODBUS/TCP and bring them into the DCS via Ethernet.

The mechanics of making this conversion are 1) put the HART transmitters into a digital mode and 2) using DIN-mount terminal blocks wire the transmitters into a HART network of 16 transmitters each. The Moore Industries HES HART to Ethernet Gateway System is the HART to Ethernet converter capable of being the HART master for four networks. One HES gives you 64 temperatures converted to MODBUS/TCP, unless your transmitters have dual inputs, in which case the count would be 128 temperatures from one HES.

Key Attributes:

  • Keeping the signal digital increases accuracy and saves money
  • Mounting temperature transmitters in junction boxes close to the process unit reduces thermocouple extension wire and all the associated problems
  • Converting your HART signals to Ethernet saves or repurpose all those analog inputs cards

There are many situations in which an additional alarm is needed on a loop where all of the available wires have been used. When that happens, the easiest and most economical solution is to add a loop powered alarm that has low power requirements.

Add an Alarm to an Existing Loop
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One example application is the need for a warning Alarm, a shutdown Trip, or an On/Off control contact. The Moore Industries ALX 2-Wire Alarm Trip draws its power to operate from its 4-20mA input signal and requires only 6.3 V from the loop to operate. If there is a 4-20mA loop already, all that is needed is to cut one wire and put the ALX in series with the 4-20mA.

Plus, because the ALX is certified Explosion-proof / Flame-proof by global agencies, it can be installed anywhere.

Key Attributes:

  • Easily added to an existing loop
  • Low power requirement
  • Certified explosion proof/Flameproof

A chemical facility had Safety Variables connected to the SIS and they wanted to add those variables to their Modbus Host. The safety variables they wanted to share were HART devices: Functional Safety HART Temperature Transmitters.

The HCS HART Concentrator System HART-to-MODBUS RTU Converter is the ideal HART-to-Modbus converter, but it cannot be connected to the safety loops directly as that would violate IEC61508 guidelines.

Safety Variable to MODBUS RTU
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To each safety loop, the SSX HART Functional Safety Isolator is added to provide air-gap isolation between the safety loop and the HART-to-Modbus converter. The exida® approved, SIL 3 capable SSX is certified for use in Safety Functions. The isolator is designed such that the HART digital signal crosses the air-gap isolation.

The output of each safety isolator can then be wired in a HART multidrop network and connected to the HART-to-Modbus converter. The HCS reads all of the HART dynamic variables and diagnostic data in the temperature transmitters and stores all of the data in Modbus registers awaiting the communication request from the Modbus Host.

The SSX safety isolator is a powerful tool to get more functionality from any safety functions.

Key Attributes:

  • HART-to MODBUS conversion with the HCS
  • Isolation from SIS with SIL-3 capable SSX Isolator
  • All dynamic variables and diagnostics are safely delivered from the temperature transmitters in the safety loop to the SCADA System via MODBUS

The thermal conductivity of pure H2 makes for an efficient cooling medium for generators. However, under normal use contaminant like oil, vapor, water or air decrease the purity of the H2. As the H2 contaminates cooling efficiency decreases and generation output decreases.  That leads to loss of revenue and replacement power costs.

It is not unusual to have alarm contacts integral to your H2 Purity Analyzer. However, the commercial issues are important enough that many will have a redundant trip source for this application.

Critical Trip H2 Purity
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Our SPA2 Programmable Limit Alarm Trip’s 20-bit input resolution with the Low Limit Process Alarm feature ensures that you will be notified when H2 purity decays.

The SPA2 can perform process alarming plus diagnostic alarming with as many as four output relays. Input and relays are all user configurable. You can choose to latch your relays to force acknowledgment. The display is a full 5 digits and also has 5 alpha characters for your engineering units. Power the unit with AC or DC as the power supply is auto sensing.

Key Attributes:

  • Process and diagnostic alarming
  • Up to four output relays
  • Site- and PC-Programmable with password protection

Monitoring cathodic protection rectifiers is important to verify their proper functioning. There may be rectifiers located in areas where you have no RTUs or PLCs available to get the rectifier signals on the network and back to the SCADA. In those cases, you will want an instrument that will measure all your rectifier signals and digitize them to be radioed back to the SCADA. A good choice of instrument for this is the Moore Industries Cathodic Protection Monitoring System (CPMS).

Cathodic Protection Monitoring System
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The typical signals off your rectifier is DC output voltage 0-100V, DC current through a metering shunt producing 0-100mV, Structure to reference voltage -5V to 0 to +5V and you may have rectifier temperature from a transmitter 4-20mA. Rectifiers commonly have redundant AC feeds and you will want to monitor the circuit breakers for each in the form of a discrete input.

Moore Industries’ CPMS can be configured to monitor one or two rectifiers. Once the rectifier signals are measured, they are stored in MODBUS registers and can be read either using serial MODBUS RTU or Ethernet MODBUS/TCP.

GPS can be added so banks of rectifiers can be turned off to better measure your pipeline voltages.

Key attributes: 

  • Simultaneous dual MODBUS RTU and Ethernet communications
  • Quick and simple programming using a web browser
  • GPS Time feature provides an optional method for keeping accurate time

Check out the CPMS in the Moore Industries’ catalog

A refinery uses a hard, ceramic lining in their fluid catalytic cracking unit (FCCU) reactor for greater wear resistance to abrasion.  Ceramics, however, can develop cracks often caused by fast temperature changes. The cracks then get battered by the particulate matter and the cracks can enlarge. Should constant temperature shocks cause ceramic failure you need to be alerted. The ceramic is also a temperature insulation between the fluid and the outer metal reactor skin. One way to detect failure of the ceramic is to monitor the reactor skin temperature. A hot spot is a sign of trouble.

Reactor Skin Temperature Monitoring
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A very cost-effective instrument package to get all those skin temperatures into your DCS is the TCS Temperature Concentrator System. It starts with the TCM Temperature Concentrator Module which has 16-channel temperature inputs, with each input being sensor configurable. The native output of the TCM is HART, but if you prefer, we can convert that to Modbus RTU. Two TCMs can be converted to Modbus by using one HMC HART-to-Modbus converter. If you still have more points to collect, you can duplicate this system as many times as needed and then multidrop the Modbus communication from each of the HMCs back to your DCS.

Key Attributes:

  • Class 1, Div 2/Zone 2 or Intrinsically Safe with barriers
  • Ambient tolerance: -40 to +85°C
  • Temperature to Modbus: Once it’s digital; keep it digital

Many industries rely on the availability of water for their processes and to succeed in the current climate, companies must adapt to the changing conditions. Major companies are now marketing their “green” credentials.  With iron ore mining, saving water in the washing process can lead to further savings down the process chain where water usage could be as high as 800 cubic meters/hour for the processing of 800 tons/hour of ore.  The primary water source is saline water from underground bores, they manage the water resource with water re-injection, and the process owner is accountable for the water use. To achieve this the engineers require an improvement in accuracy over the existing 4-20mA loop from the magnetic flowmeters to their PLC,  where they have also identified the totalization of the pulse count from the meter is not accurate.

With the existing magnetic flowmeter, they can tap into the improved digital resolution of the meter using HART protocol and the HCS HART to Modbus Converter. The HCS is connected in parallel with the existing 4-20mA loop, and reads the primary process variable (PV) → Volume flow plus secondary process variable (SV) → Totalizer.

HART monitoring of Flowmeters to increase Accuracy
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Additional Considerations
In some applications, flow rate and flow totalization are critical variables. A facility will use a flowmeter that they believe is producing accurate flow measurement and integration, but by the time that data gets into the SCADA, the values are questionable. There are several variables that may contribute to the questionable data quality like the accuracy and resolution of your input cards or timing issues in reading a pulse output.

Reading the data digitally can eliminate any and all variables. Since the flow rate and totalization are already digital in the flowmeter, a HART master product like the HCS can be used because it takes the 32-bit floats from the flowmeter and delivers them as MODBUS 32-bit floats to the SCADA. Once the rate and totalization is digital, it is best to keep it digital all the way back to the destination, and the HCS accomplishes that with its serial MODBUS RTU, RS-485 output. If Ethernet communications is required instead, the HES HART to Ethernet Gateway System outputs over Ethernet using the MODBUS/TCP protocol.

Key attributes:

  • Keeping the signal digital increases accuracy and saves money
  • HART to MODBUS conversion
  • Get more data to your SCADA system

Excessive wellhead pressure can cause serious consequences to downstream personnel, production and production assets and the environment. It is therefore commonplace to have IEC 61508 compliant protection systems. Companies implement various strategies but most common are 1oo2 or 2oo3 architectures for compliance to SIL 2 or SIL 3.

Wellhead HIPPS
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The STA Functional Safety Limit Alarm Trip logic solver was designed for such SIF (Safety Instrumented Function) executions and is certified by exida for use in Safety Instrumented Systems as SIL2/3 capable. The simple user interface is most beneficial to a cross-section of users. Plus, its high ambient temperature specifications and Class I, Div 2 / Zone 2 certification make it suitable for any upstream installation. The STA also has high RFI and EMI Immunity to minimize nuisance trips due to noisy environments.

Key attributes:

  • Exida approved for use in a Safety Instrumented System
  • The SIL 2/3 Capable STAs are much simpler to program than safety PLCs and cost significantly less
  • Suitable for extreme environments

When a refinery’s analytical shelter is upgraded, the number of measurements typically increases instead of decreases. It is a common experience that insufficient numbers of wires are available to send additional signals back to the BPCS or SCADA package. It is well known how expensive it is to lay new wires, especially when they transverse hazardous areas, so most facilities seek a more economical and effective alternate technology, such as Remote I/O.

Even Refineries Run Out of Wires
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Remote I/O systems, such as the Moore Industries NCS Net Concentrator System, can be mounted in or near the shelter with the signals that need to be sent to and from the SCADA being wired to the NCS I/O modules. This removes the need to send signals using the underground wiring, making that wire available for RS-485 serial communications (MODBUS RTU) back to the host, and eliminates the need for any additional wires.

Naturally, the installed infrastructure will vary for each analytical shelter. When a facility has an Ethernet network already installed that can be used with the NCS which has an Ethernet connection and MODBUS/TCP protocol as standard features. It includes three independent communication ports, 2 serial and 1 Ethernet, allowing multiple systems to poll the same data.

Key attributes:

  • Wide range of I/O types and number of points
  • Ethernet connection and MODBUS/TCP protocol as standard features
  • Class I Div 2/Zone 2 approval and -40 to 85C ambient operating environment

Refineries have the need to share process signals across multiple systems. Steam flow from a process unit, for example, might have to be shared with the powerhouse.

Signal Isolator Repeater Splitter
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Invariably you will share or split this primary process variable (PV) off to the secondary system through an Isolator. The isolator assures that the primary loop will continue functioning should accidents or maintenance disable the secondary loop. In order to ensure that the secondary area does not have access to the transmitter’s HART signal, choose an isolator such as the Moore Industries ECT-DIN Signal Isolator and Converter. It is loop-powered by the secondary system (PLC) and it blocks the HART digital signal.

Key attributes:

  • ECT is a signal splitter whose output follows failed inputs down below 3mA
  • HART Blocking
  • Superior RFI/EMI and common mode noise rejection

MODBUS is very popular in the oil and gas upstream market while loop-powered HART transmitters still dominate and minimize your wiring. The problem is combining the two protocols effectively and economically.

Convert Tank Battery Levels to ModbusDownload the PDF file 

The Moore Industries HCS HART Concentrator System HART-to-MODBUS RTU Converter is a very popular solution. The front-end of the HCS is a HART master which polls each of the HART devices grabbing all the Dynamic Variables and all the diagnostic bytes if desired. The data are stored In MODBUS registers waiting for the SCADA or RTU to make the request. The communication physical layer is RS-485 serial.

Should Ethernet communications be preferred instead of serial, the HCS  has a sister product, HES HART to Ethernet Gateway System, which uses MODBUS/TCP over Ethernet

Key Attributes:

  • Keeping the signal digital increases accuracy and saves money
    • Simple configurable HART to Modbus converter
    • Up to 16 transmitters on HART network
    • Poll all Dynamic Variables + all Diagnostics
  • Class I, Div 2 certified
  • Ambient tolerance -40 to +85°C

Natural gas is transported at high pressure, however, it is distributed to industrial users at a lower pressure. Pressure reduction stations are used at these distribution junctions to reduce the gas pressure using a throttling valve. However, a large reduction in pressure will cause a significant drop in temperature of the gas of approximately 5°C for each 1000kPa reduction in pressure, known as the Joule-Thompson effect. The natural gas must be heated using an indirect  Water Bath Heater  (WBH) before the pressure is reduced in order to avoid the formation of ice crystals and hydrates which can cause major damage to equipment. If preheating is not applied within the process, equipment may also experience embrittlement of piping and fittings, and blockage of filters and regulator/valve seats.

Gas Transmission Pipeline Indirect Water Bath Heater TripsDownload the PDF file

Water bath heaters burn a fuel such as fuel gas or fuel oil within the horizontal “U”-shaped firebox immersed in the lower portion of the water bath. The heat released by the burning fuel is quickly transmitted through the fire tube wall to the water bath, maintaining it at the desired temperature. The fluid to be heated (natural gas, oil, process fluids) flow through the process coil of the heater which is immersed in the upper portion of the water bath. Heat is transmitted from the hot water bath through the tube-wall to the fluid inside the process coil.

The heater temperature controller maintains the water bath temperature at the desired level by controlling the firebox fuel gas supply. A temperature of 87 ˚C is considered the maximum temperature for operation. It is best to operate the heaters at less than 87 ˚C when inlet condition and/or outlet temperature requirements allow. Operating the bath temperature at the minimum temperature required to give hydrate protection in either the pipeline or separator not only saves fuel, but provides maximum liquid recovery in the downstream equipment.

Water bath heaters may also be used for heating transfer fluids; regeneration gas heating, vaporizing and superheating LPG and LNG; and heating sensitive gases and fluids, such as crude oil, helping to reduce its viscosity and enhance separation efficiency in upstream process units.

The safety of these heaters is paramount, given the environment in which they operate. IEC61508 certified SIL2/3 capable  Alarm Trips such as the Moore Industries STA Safety Trip  Alarm are commonly employed in the protection systems of indirect Water Bath Heaters for high temperature trips on Flue stack, Low Pressure Switch for Fuel gas, and can be used to alarm on overpressure heater tank, burner failure, changes in fuel pressure, low water level, and low heat output.

The STA Safety Trip Alarm is exida certified up to SIL 2/3 capable, can detect abnormal operating conditions (Hi Temperature – Hi & Lo Pressure) and provide Fail Safe relay outputs to independently manage the safe operation of the water bath heater.

Key attributes:

  • Class I Div 2/Zone 2 approval and local display
  • Third-party exida certified SIL2/3 capable
  • Multiple trip voting available if needed

Download the STA data sheet, or view the STA in the online catalog.

High pressure natural Gas pipelines criss-cross every continent, and many countries. The United States alone has more than 200 existing natural gas pipeline systems, which together form a network of nearly 500,000 km of gas transmission1.  These pipelines need to mitigate the risk of explosion due to pipeline ruptures. There are several possible causes of failure, external interference is historically the main cause of loss of gas and accounts for about 40% of all incidents leading to a release of gas.  Corrosion accounts for up to 15% of all historical incidents, and material failure / Construction defect / is known to account for up to 15% of all incidents2.

Gas Transmission Pipeline Rupture ProtectionDownload the PDF file

Automatic protection systems are employed to close valves and prevent the release of gas in the event of a pipeline break. These systems are critical to safe, economic operation of the pipelines.  A proven reliable method to identify a pipeline break is to detect the “abnormal” value of the rate of pressure drop (DP/DT) relative to values established during the normal operation of the pipeline. An alarm trip is used to monitor these conditions and alert the control system when set parameters have been exceeded.

The Moore Industries SPA2 Alarm Trip continuously monitors pipeline pressure dynamics to provide early detection of pipeline pressure changes. The alarm trip can be used to provide operator warnings or initiate valve execution. Closure of the Main Line Valve on either side of the leak can be triggered automatically by an excessive sustained sudden drop in line pressure.  These systems, used in conjunction with other devices and systems, can mitigate a rupture.  The SCADA system, which includes telemetered data from the valve stations, keeps the operator informed of abnormal events giving him the option to take further action.

Key attributes:

  • Rate-of-Change alarming and absolute pressure alarming can be combined in a single unit
  • Up to four SPDT relays rated at 5A 250VAC/24VDC
  • Suited for installation in Class I Div 2/Zone 2 locations

1.United States Studies Centre, It Doesn’t Have To Be This Way.
https://www.ussc.edu.au/analysis/australias-energy-crisis-americas-energy-surplus   

2.APA, PRELIMINARY HAZARD ANALYSIS OF THE NATURAL GAS DELIVERY, P.27
https://www.apa.com.au/media/175530/ywl%20preliminary%20hazard%20analysis.pdf

Many applications require a control valve to remain in the position it held prior to loss of power or loss of signal from the control system: Valve Hold in Place or Lock in Last is applied upon loss of the control signal. The Valve Hold in Place strategy uses solenoid valves in the Open/Close airlines between the positioner and actuator and it uses a trip amplifier, like the Moore Industries Model ECA, monitoring the 4-20mA control signal.

Alarms 2 Valve Hold in Place at Loss of Electric Signal

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The relays of the trip amplifier are controlling the Open/Close status of the solenoid valves.  In normal operation the two solenoid valves are energized and the valves are open allowing passage of the air from the positioner to the actuator. Upon loss of the 4-20mA control signal, the trip amplifier de-energizes its relays closing the solenoid valves. With the solenoids closed the air is trapped within the actuator’s loading chamber, locking and holding the control valve at the last position. Because the trip amplifier’s relays are failsafe, the same solenoid closures would occur upon power failure to the trip amplifier. When loss of signal or failure occurs a secondary contact alerts the controller that the valve is in a Hold in Place position.

The trip amplifier can switch solenoids with a coil voltage up to 250 VAC/5A or  30VDC/5A. The response time of the trip amplifier to a loss of the control loop is <50mS.

Key attributes:

  • Fast speed of response for the failsafe relays
  • Contacts ratings for both DC and AC solenoids
  • Fully-adjustable trip point

A temperature excursion on the HPump system motor, when discovered in time, can mean that only some minor maintenance is needed. If that same temperature excursion isn’t caught early-on, however, components such as front and rear bearings, windings, and thrust bearings can be damaged. Repairs are very costly and could impact production.

Alarm System Added to your HPump I/O System

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The Net Concentrator System (NCS), a rugged I/O system that can handle the harsh environments surrounding these pumps, will measure all the temperatures and deliver them back to the SCADA or control system as MODBUS. More importantly in terms of motor protection, the NCS I/O hardware has a simple configurable alarm capability called the Multiple Analog Alarm (MAA) that provides relays for warnings or trip functions. When the MAA is applied, the SCADA can also read the same alarm warnings and trips as MODBUS registers.

Key attributes:

  • Wide range of I/O types and number of points
  • Flexible alarm application that is configured through the on-board web server
  • Class I Div 2/Zone 2 approval and -40 to 85C ambient operating environment

HPump is a trademark of Baker Hughes Incorporated

Covid 19
With the emergence of the coronavirus COVID-19, we felt it is important to inform you on how Moore Industries is responding to the unfolding situation.

We remain fully operational in support of essential businesses and services. We are continuously monitoring the events surrounding COVID-19, following information provided at local, state, national and international levels regarding measures being implemented to contain the virus and it’s expanding impact.  While we will continue to respond to this evolving situation to ensure the safety of our employees, clients and partners, we remain committed to providing you with the same high level of quality and reliability of product and support that you have come to expect.

Company operations put in place balance production and support needs with our employee’s health and safety.  With constant monitoring of local, state and national health regulations and recommendations, we will strive to effectively adapt as necessary to the changing needs of our employees, community and customers.

Specific actions we have taken include:

  • Daily cleaning procedures to reduce viral transmission on surfaces and materials
  • Non-essential travel has been suspended
  • Only essential personnel are allowed in the manufacturing facility and sales offices
  • Telecommuting work policy implemented for employees whose jobs allow it
  • Face-to-face meetings are restricted and protocols for social distancing established

We recognize that you, your family and your organization have challenges too during these difficult times. Our thoughts and best wishes go out to you as you also adapt to the quickly changing crisis facing all of us.

Please contact us if you need to discuss any concerns.

It is becoming increasingly more common to bring process measurements into our systems using Ethernet. The Moore Industries TCM Temperature Concentrator Module has been available with HART communications plus Modbus RTU serial for many years. The HES HART to Ethernet Gateway System converts HART data to Modbus/TCP and thus opens up the option to bring the data into the host using Ethernet.

64 Temperatures into DCS or SCADA via Ethernet
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The TCM measures 16 temperatures from thermocouples or RTDs. It can be located close to the process because it has excellent ambient temperature specifications and is certified Class I, Div 2 and Intrinsically Safe. The loop-powered TCM will send its data back to the HES via HART protocol.

The HES is available as a single channel or four channel gateway. The signal channel model converts 16 temperatures to Modbus/TCP and the four channel model converts 64 temperatures to Modbus/TCP. Each HES retrieves process variable data with HART command 03 or command 09. It also retrieves all the diagnostic data with command 48, making it a very effective gateway to use with Asset Management Systems.

Key Attributes:

  • Ambient Temperature: -40 to 85°C
  • HES embedded web server makes reading data and identifying Modbus registers simple
  • TCM has a universal temperature front-end for any sensor

Corrosion of production structures and pipelines is costly in terms of the environmental impact and production loss. Impressed current protection systems can protect those structures but the Rectifiers should be monitored to assure proper functionality.  If an RTU is already installed near the rectifier and the RTU is on the SCADA network, connecting the rectifier to the SCADA is quite simple. We simply connect the rectifier signals to the local RTU.

Cathodic Protection Rectifier MeasurementsDownload the PDF file 

Signal conversion is typically required for the high DC Voltage and Current outputs of the rectifier. Moore Industries’ has provided thousands of ECT Signal Isolator and Converters over the years to make these exact signal conversions. One model of ECT converts the rectifier voltage output of 0-100Vdc or 0-50Vdc to 4-20mA. The high level of DC Current output (0-100A or 0-50A) passes through a metering shunt which produces 0-50mVdc. Another model of ECT converts the 0-50mVdc into 4-20mA signals which are easy for the RTU to process.

The ECTs are most commonly output loop-powered by the RTU, but they can be provided to be mains (or line) powered.

Key Attributes:

  • Ambient temperature: -40 to 85°C
  • Isolation: 1500Vrms
  • Housing: Rugged Aluminum DIN mount enclosure

Wastewater treatment plants not only handle waste but often times turn that waste into electricity. In order to keep these small bio-electric plants running efficiently, they have to monitor and control temperature. 

Digester Temperature Monitoring
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The TDZ3 Smart HART Temperature Transmitter and full assemblies offer dual input capability, advanced diagnostics, 20 bit input resolution and a five year repeatability specification that will keep your digester and downstream co-generation plant running smoothly and efficiently. The TDZ has worldwide hazardous approvals and is configurable with any HART compatible host or handheld and is also DTM programmable with any FDT compliant host, such as PACTware.

Key Attributes:

  • Dual input and advanced diagnostics
  • Superior five year repeatability specification
  • Full temperature assemblies available

Due to their efficiency and energy savings, VFDs (Variable Frequency Drive) are replacing AC and DC motors in water and wastewater facilities. Unfortunately, VFDs can generate a lot of high frequency noise that can wreak havoc on control and monitoring devices such as PLCs and distributed control systems.  Good shielding and grounding schemes will certainly mitigate these issues but many facilities are quite old and don’t have the adequate time or resources to constantly troubleshoot the sources of common mode noise.

VFD Noise
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If this is a common challenge at your facility consider installing the Class I Div 2, UL approved ECT DIN signal isolator.  The ECT is housed in a rugged RFI/EMI immune case and provides a high level of common mode noise rejection that will filter out the extraneous high frequency noise that is on the 4-20mA signal from the VFD. The ECT is a two wire, output loop powered device and receives its power from the DCS or PLC input card. 

Key Attributes:

  • High common mode noise rejection
  • UL and Class I Div 2 approved
  • Excellent RFI/EMI immunity

Chlorination metering and accurate dosing is a critical process at all water plants.  Sometimes dual or redundant metering and dosing are required. 

Redundant Metering Pumps
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When this need arises consider the ECT DIN Signal Splitter.  The Class I Div 2/Zone 2 ECT splitter receives one input from a flowmeter or other transmitter and produces two identical and fully isolated outputs to two other remote locations.  This allows full redundancy when required and allows either of the two outputs to be disconnected (online maintenance) without having an effect on the other.  The ECT is a four wire device powered with 24DC, 117VAC, or 230VAC and offers loop input power to the flowmeter or field transmitter when required.  The metal case provides excellent immunity to RFI/EMI noise.

Key Attributes:

  • Two fully isolated and independent outputs
  • Input loop power for any two wire field transmitter
  • Excellent RFI/EMI immunity

You can’t always plan for every loop condition when starting your facility up.  Sometimes input cards are active and sometimes passive. Transmitters are sometimes line powered (four-wire) which usually have active outputs, and sometimes they are passive (two-wire). Did the contactor install the right input cards on the PLC?  Does the building automation system read HART input? 

HART Signal IsolatorDownload the PDF file

When those unplanned situations exist, you can turn to the HIT HART Pass-through Signal Isolator. The HIT isolator provides superior noise rejection and full three-way isolation with HART pass-through capability.  Another very important feature of the HIT that is that the output will track the input all the way to 0mA when it fails; as opposed to most other isolators that simply go to 4mA – which is always difficult to ascertain between a failure of the input or just 0% scale. Lastly, the HIT can be used on non-HART or HART based loops when asset managers need that valuable diagnostic and calibration data.

Key Attributes:

  • Class I Div 2/Zone 2 approval
  • HART pass-through capability
  • Output tracks to 0mA on failed input

Pharmaceutical and semiconductor building and process unit temperature control require sensitive and accurate measuring sensors and transmitters. 

Pharma semi 2
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Moore Industries offers an entire family of sensors and transmitters designed especially for these building automation and process room needs. Additional drawings, specifications and installation recommendations can be found on our Hi-Tech Datasheet.

Key Attributes:

  • Special duct mount designed sensors
  • Unique Duct Mount Averaging Sensor that ensures most accurate measurements
  • NIST traceable calibration certifications available

In the early stages of refining crude oil has to go through selective hydrogenation steps.  During these steps, the temperature is a key process variable that has to be monitored carefully.

Refinery Selective Hydrogenation Unit

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When critical temperatures have to accurately and reliably be monitored, turn to the TDZ3 Smart HART Temperature Transmitter.  The TDZ3 is a dual input capability that allows two sensors to be monitored in a primary and secondary configuration.  Should the primary sensor fail, the TDZ3 will automatically switch over to the secondary sensor and send out a HART diagnostic alarm. The TDZ3 also has advanced sensor diagnostics that allow sensor drift detection and thermocouple impedance levels for thermocouple burnout situations.  The TDZ3 also comes with full worldwide hazardous areas approvals.

Key attributes:

  • Dual input for failover/backup
  • HART or DTM programmable
  • Advanced sensor diagnostics and worldwide hazardous areas approvals

Thermocouple extension wires are not only expensive but are a primary culprit of measurement error over time.  Corrosion and susceptibility to plant noise are common sources of measurement error due to long TC extension wire runs.

Refinery Hydrocracker Upgrade

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Hydrocrackers used a lot of thermocouples.  You can reduce lead wire expenses and thermocouple measurement errors by taking a different approach of installing DIN rail temperature transmitters in the field, close to the process, and running shielded twisted pair back to the DCS.  The Class I Div 2/Zone 2 approved THZ3 Smart HART Dual Input Temperature Transmitter is a highly accurate and repeatable DIN rail temperature transmitter with advanced diagnostics. 

If your control system’s input cards can read HART, you can further reduce your measurement cost per point by bringing two sensors to each THZ3 and reading the PV and SV dynamic HART variables, which represent Sensor 1 and Sensor 2 respectively.

Key Attributes:

  • Class I Div 2/Zone 2 approved DIN version of THZ3
  • Dual input capability may reduce cost per point
  • High ambient operating temperature range of -40 to 85C (-40 to 185F)

In refineries, the temperature is one of the highest volume measurements that exists.  Reducing the cost of these measurements, which are often in hazardous areas, is always a top priority. 

Intrinsically Safe 32 channel Temperature Multiplexer
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When you have several temperature points that are located in hazardous areas, look to the TCS Temperature Concentrator System. The TCS consists of one or two TCMs and an HMC. The TCM is a 16 channel universal temperature multiplexer that communicates to the HMC via HART.  The HMC in turn converts the HART temperature data into MODBUS RTU protocol for the DCS to read. The TCM can be installed in Class I Div 1/Zone 0 areas and can multiplex up to 32 channels of temperature per HMC. This drastically reduces the temperature cost per point as opposed to running sensor extension wire all the way back to the DCS or control room.

Key attributes:

  • 32 channels of multiplexed temperature reduces the cost per point
  • PC programmable TCM and HMC with free programming software
  • Worldwide hazardous area approvals

Industries such as mining operations, pharmceutical, pulp or paper manufacturing have conveyor belt systems that should they run too fast or too slow could cause dangerous process conditions downstream. Due to the criticality of these belt speeds, Safety Instrumented System (SIS) may be implemented to protect the process and personnel.

Conveyor Belt Speed Protection and Monitoring
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When conveyor belt speed monitoring is important, consider the FDY PC Programmable Frequency-to-DC Converter. The FDY  monitors frequency, period, high or low pulse width, and contact closure signals and converts it to a linear and isolated 4-20mA signal.  The two-wire loop powered FDY has worldwide hazardous areas approvals and sets up in just a few minutes with easy to use PC programming software.

Key Attributes:

Many facilities have processes that deal with dangerous gasses and chemicals that could leak under accidental or abnormal process conditions. A layer of protection or alarm system typically referred to as a Safety Instrumented System needs to be implemented in order to protect personnel and the environment.

SIL 3 Capable Logic Solver – Gas Alarm

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Protect personnel and the environment with the STA Functional Safety Trip Alarm as your Safety Instrumented System logic solver by monitoring the gas levels and shutting down the process when a leak or abnormal process disruption takes occurs. The STA is simple to program and has an auxiliary analog output for retransmission to a separate host system. The STA is SIL 2/3 capable, approved by exida and rated Class I Div 2/Zone 2.

Key attributes:

  • SIL 2/3 capable and exida approved
  • SIL 2/3 capable and exida approved
  • Easy programming
  • Class I Div 2/Zone 2 approval and local display

Many manufacturing facilities have many process loops where a bank of displays or panel meters are needed for installation in control rooms or in remote cabinets.

1/8 DIN Panel Display/Meter
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When a panel meter display is required, consider the Nema 4X 330R 1/8 DIN Process Display and Panel Meter.  The 330R has a large 4 digit LED display and accepts all T/Cs, RTDs, mA, V and millivolt inputs.  The unit is powered with any voltage between 90-250VAC and is to program through the front pushbuttons and easy to navigate the menu. The 330R has additional options that include analog retransmission, two SPDT alarms and a loop power supply to power a two-wire instrument that is tied to its input.

Key Attributes:

  • Easy to program and large 4 digits LED display
  • NEMA 4X front and universal AC power supply
  • Options include: Two alarms, analog retransmission and loop power supply

Manufacturing facilities often have many process loops where the transmitter’s local display is either remote or not at eye level. 

Large Field Mount Loop Indicator/Display

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When loops require local indication for operations or plant personnel, consider the Nema 4X SPD PC Programmable Loop Display that only consumes 2.3 volts. The SPD is a loop powered or line powered (unit with alarms) indicator with a full five digits for process variable and engineering units (EGU) readout. The SPD has an optional backlit LCD and two SPDT alarms. 

Key Attributes:

  • Large loop display that is easy to program with free software
  • Worldwide hazardous area approvals
  • Backlit LCD and two alarms optional

Manufacturing facilities have many process loops where the transmitter’s local display is either remote or not at eye level. 

Field Mount Loop Indicator/Display
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When loops require local indication for operations or plant personnel, consider the PSD PC Programmable Loop Display. The PSD is a loop powered indicator with a full five digits for process variable and engineering units (EGU) readout.  A loop maintenance diode option is available that allows the removal of the PSD from the loop without disrupting or breaking the current loop.  The PSD is PC programmable with free easy to use software and even allows a 128 point custom curve creation for non-linear signals.

Key Attributes:

  • Easy to program with free software
  • Worldwide hazardous area approvals
  • Loop maintenance diode allows removal of PSD from loop with no effect

Manufacturing facilities have many processing areas that require layers of process protection to prevent unnecessary exposure to dangerous situations that may harm personnel or the environment.  Most  facilities have implemented Safety Instrumented Systems (SIS) in compliance with IEC 61511 to mitigate the exposure to such dangerous events.

SIL 3 Capable Loop Display/Indicator
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When Safety Instrumented Functions (SIF) that make up the SIS are implemented, many of those loops will require a remote local indication of critical process variables for operators and technicians. The exida approved Functional Safety Series SLD Loop Display is IEC 61508 certified to use in these safety loops.  The SLD was designed for critical loops and as such has a loop maintenance diode so if the SLD needs to be removed from the loop, the primary safety loop continues uninterrupted.  With SIL 3 capability safety practitioners can install this loop indicator on any of their plant wide SIFs.

Key Attributes:

  • exida approved to IEC 61508
  • Worldwide hazardous area approvals
  • Loop maintenance diode allows removal of SLD from loop with no dire consequences

Industrial compressors are often used in large facilities to supply headers with air for pneumatic instruments and valves.  These compressors have to run at precise speeds.  If these compressors start to run too fast they can become very dangerous and expensive to repair. 

SIL 3 Capable Frequency to DC Converter
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If you have compressors or rotating equipment that is critical enough to require a Safety Instrumented System, consider the Functional Safety SFY PC Programmable Frequency-to-DC Converter.  The SFY is an exida approved SIL 3 capable frequency-to-DC transmitter that monitors frequency, period, high or low pulse width, and contact closure signals and converts it to a linear and isolated 4-20mA signal.  The two-wire loop powered SFY has worldwide hazardous areas approvals and sets up in just a few minutes with easy to use PC programming software.

Key Attributes:

  • exida approved SIL 3 capable
  • Local display and Free PC programming software
  • Worldwide hazardous area approvals

Many manufacturing facilities have several critical points of temperature that has to be monitored.  Some of these are so critical that they are part of a Safety Instrumented System (SIS). 

SIL 3 Capable Temperature Transmitter
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When these critical SIS temperature measurement needs arise, consider the Functional Safety STZ Smart HART Dual Input Temperature Transmitter for your Safety Instrumented Functions (SIF).  The STZ is an exida approved SIL 3 capable temperature transmitter featuring dual sensor input capability that allows for failover or backup mode when primary sensors fail.   The STZ transmitter family can be HART or DTM programmed and carries worldwide approvals.

Key Attributes:

  • exida approved SIL 3 capable temperature transmitter
  • Backup or Failover mode on a primary sensor failure
  • HART or DTM programmable with worldwide hazardous area approvals

Many processes require critical cooling water lines for in-line process operations or for emergency cooling.  If a process doesn’t get the required cooling water or a process temperature cannot be lowered quickly enough, layers of protection have to be put in place.

Critical Flow Monitoring – Safety Signal Splitter
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Due to the dangerous nature of these types of situations, Safety Instrumented Systems (SIS) are often implemented.  Often these flow rates are also monitored by the Basic Process Control System (BPCS) too.  When this is a requirement, look to the Functional Safety Series SST Safety Splitter.  The four-wire SST is an exida approved SIL 2 capable signal splitter, with Class I Div 2/Zone 2 approval, that sends your critical process signal to two remote locations.  The SST also passes valuable HART diagnostic and process variable data through the SST in case asset managers need to view calibration or other essential diagnostic data from the field transmitter.

Key Attributes:

  • exida approved and Class I Div 2/Zone 2, SIL 2 capable for SIS loops
  • Full four way isolation up to 500Vrms between power and all input/outputs
  • Passes critical HART data from field transmitter

Many manufacturing facilities and operations have critical monitoring areas like high pressure steam lines that if not monitored closely could cause serious injury to personnel and process equipment.  Often Safety Instrumented Systems (SIS) are put into place after HAZOP studies. 

IEC 61508 Certified SIL 3 Capable Signal Isolator/Repeater

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If the SIS is implemented consider looking to the SSX Functional Safety Signal Isolator.  The SSX is an exida approved SIL 3 capable isolator with HART pass-through capability.  The SSX allows you to share that critical process variable, whether steam or temperature, with both your SIS logic solver and your Basic Process Control System or Asset Manager.  This affords you the protection and added safety by not having to worry about losing your primary safety loop when you work on your secondary BPCS-side loop.

Key attributes:

  • SSX is exida approved and SIL 3 capable
  • Class I Div 2/Zone 2 approvals
  • HART pass-through allows critical signals to be shared with asset manager

Upstream oil and gas, mining, and metal processing operations and food and beverage facilities oftentimes have processes that deal with critical pressures that could spike during abnormal process conditions. A layer of protection or alarm system typically referred to as a Safety Instrumented System needs to be implemented in order to protect personnel and the process.

SIL 3 Capable Logic Solver – Pressure
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Protect personnel and your process with the STA Functional Safety Trip Alarm as your Safety Instrumented System logic solver by monitoring pressure levels and shutting down the process when a spike or abnormal process disruption takes occurs. The STA is simple to program and has an auxiliary analog output for retransmission to a separate host system.   The STA is SIL 2/3 capable, approved by exida and rated Class I Div 2/Zone 2.

Key attributes:

  • SIL 2/3 capable and exida approved
  • Easy programming
  • Class I Div 2/Zone 2 approval and local display

Most manufacturing operations are full of HART smart instruments.  Often there are additional process variables from these HART devices that are being measured but simply can’t be monitored because the field device only has one 4-20mA output.  If the DCS or BPCS is HART capable then these hosts could poll these smart HART instruments for this additional diagnostic and process data. Unfortunately upgrading older input cards or legacy control systems to be HART smart compatible can be quite expensive.

HART Mux – Smart Valve Diagnostics
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When this condition exists, utilize the Class I Div 2/Zone 2 approved HIM HART Interface Module.  The HIM has the ability to poll any HART smart device and turn its digital HART process measurement data into 4-20mA signals (up to three) for retransmission to any host.  In addition the HIM has optional alarm relays (up to two) that can be used to alarm on anything from diagnostic bits, transmitter status to process variable limits.  The HIM is even multi-drop capable with an optional MODBUS RTU output that allows a remote MODBUS RTU host to poll it for the field transmitter’s HART variables; thus turning the HIM into an industrial HART-to-MODBUS gateway. 

Key Attributes:

  • HART to Analog Conversion: up to three AOs and two relay alarms
  • Local display
  • Class I Div 2/Zone 2 approval

Most process facilities have a lot of valves controlling chemical feedstock, finished product, steam and water. The top works (actuators) are being upgraded on most valves to include a smart HART positioner.  These positioners offer tighter control and provide a lot more diagnostic and process data.

HART to MODBUS Gateway – Smart Valves

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If your facility has smart HART positioners on valves, and you would like an efficient way to monitor these valves at a central monitoring location, consider the HCS HART Concentrator System.  The HCS is HART-to-MODBUS RTU gateway that can be multi-dropped throughout your facility on one twisted pair and connected to a central MODBUS RTU host or SCADA system.  The HCS is a HART master and polls the smart HART positioner for its process variable data points, such as stem position, stroke percentage, temperature, set point and diagnostic bits that warn of potential trouble.  This HART data is then mapped to MODBUS RTU so it can be polled remotely by a MODBUS host.  Each HCS can have up to 16 smart HART devices attached to it.

Key Attributes:

  • Queries smart HART device for process data and diagnostics
  • Converts HART data to MODBUS RTU
  • Polls up to 16 HART devices per HCS

There many HART smart instruments installed throughout all manufacturing facilities, many of which are multivariable instruments which have additional process variables that are available via the HART signal.

HART to MODBUS Gateway

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When you need access to these additional HART variables and diagnostic data, but don’t have a HART based DCS or asset manager, consider the HCS HART Concentrator System. The HCS polls between one and 16 HART smart instruments on one twisted pair and maps all of the process variable and diagnostic data to an internal MODBUS memory map. This then allows the HCS to be polled by a MODBUS RTU host making all of the HART data available. The HCS is approved for installation in Class I Div 2/Zone 2 areas and supports both RS-232 and RS-485 physical layer networks. The HCS is configuring via a free Windows PC program and sets up in just a few minutes.

Key Attributes:

  • Polls between one and 16 HART instruments and converts data to MODBUS RTU
  • Class I Div 2/Zone 2 approval
  • -40 to 85C ambient operating temperature

There many HART smart instruments installed throughout all manufacturing facilities, many of which are multivariable instruments which have additional process variables that are available via the HART signal.

HART Interface Module and HART Mux
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When you need access to these additional HART variables and diagnostic data, but don’t have a HART based DCS or asset manager, consider the HIM HART Interface Module. The HIM polls any HART compatible instrument and allows you to break out any HART dynamic variable or diagnostic bit and covert it to a 4-20mA signal or alarm, respectively.  The HIM allows you to retransmit up to three dynamic HART variables and gives you one or two alarms that can be tied to most any diagnostic bit or dynamic variable. Additionally, the HIM has redundant MODBUST RTU outputs optional. The HIM is approved for installation in Class I Div 2/Zone 2 areas and is configured via a free Windows PC program and sets up in just a few minutes.

Key Attributes:

  • Polls any HART instrument and breaks out additional HART variables and diagnostics
  • Class I Div 2/Zone 2 approval
  • -40 to 85C ambient operating temperature

Most process facilities have critical measurement variables like the pressure that if not monitored closely could cause serious injury to personnel.  Often these critical signals need to be shared with other control devices and wiring them in series with one another is not always a good idea since a failure at one receiving device renders the loop open, or in a failed state.

HART Pass-Through Signal Isolator/Repeater
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If you have critical loops like these consider looking to the HIX HART Signal Isolator.  The HIX is a rugged and reliable two-wire, output loop powered isolator with HART pass-through capability.  The HIX allows you to share that critical process variable, and any valuable HART data, with both your primary control system and your backup controller.  This affords you the protection and added safety by not having to worry about losing your primary control loop when you work on your secondary backup-side loop, and vice versa. 

Key attributes:

  • HIX provides area isolation and follows failed inputs down below 3mA
  • Class I Div 2/Zone 2 approvals
  • HART pass-through allows critical signals to be shared with the backup system

Most processing facilities have large basic process control systems that control and monitor most of the plants.  However, there are other silos of control and monitoring by PLC systems that come with other critical or specialized machinery. 

Signal Splitter - Sharing Critical Signals
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In situations where these key process signals need to be shared between these systems, turn to the ECT Signal Splitter.  The Class I Div 2/Zone 2 ECT DIN splitters accept one input and outputs two identically isolated outputs to each of the two process systems. This allows either system to be taken out of the loop without affecting the availability of the other loop.  Since the ECT splitter is a four wire unit, it has an optional input loop power supply that can be used to power the connected transmitter.

Key Attributes:

  • Full four way isolation up to 500Vrms between power and all input/outputs
  • RFI/EMI resistant and hardened aluminum case
  • Zero and span potentiometers for onsite calibration

Many process facilities have several points of temperature that have to be monitored.  Many of these measurements utilize three wire RTDs with long extension wires.  Corrosion can cause
a significant amount of error in these three wire circuits. 

Temperature Sensor Corrosion Detection - RTD
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For those cases, the TDZ3/THZ3 Smart HART Dual Input Temperature transmitters have corrosion detection capability to warn you when corrosion build up is causing measurement error.  The THZ3/TDZ3 transmitter family can be HART or DTM programmed and carries worldwide approvals. 

Key Attributes:

  • Advanced sensor diagnostics – Corrosion detection for RTD measurements
  • HART or DTM programmable
  • Worldwide hazardous area approvals

Many process facilities have several points of temperature that have to be monitored.  Many of these measurements utilize redundant or dual element RTDs and require exceptional accuracy and repeatability.

Temperature Sensor Drift Alert – Advanced Diagnostics
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For instances where two elements are used, the TDZ3/THZ3 Smart HART Dual Input Temperature transmitters have sensor drift alert detection capability to warn you when one sensor has started to drift from the other.  This is particularly useful in applications that demand an accurate and repeatable secondary sensor. The THZ3/TDZ3 transmitter family can be HART or DTM programmed and carries worldwide approvals. 

Key Attributes:

  • Advanced sensor diagnostics – Sensor drift detection for RTD or T/C measurements
  • HART or DTM programmable
  • Worldwide hazardous area approvals

Many process operations have processes that require tight pressure control.  Some processes are too critical to rely on just one pressure transmitter, since a transmitter failure could cause a nuisance or spurious trip or process upset. Furthermore, not all of these situations are in close proximity to a DCS.

High Availability Alarm System: 2oo3 Voting
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Instead of considering a sophisticated PLC and additional pressure transmitters, consider utilizing a 2oo3 voting scheme with SPA2 Site Programmable Alarm Trips by wiring their relays in a shutdown or alarm circuit scheme.  It is very easy to program vs a PLC and its SPDT relays are rated at 5A 250VAC/24DC.  The SPA2 is approved for installation in Class I Div 2/Zone 2 locations and is push button or PC programmable with quick and easy to use menus.  Each SPA2 has a local display and an optional 4-20mA retransmission.

Key attributes:

  • Simple 2oo3 voting configuration
  • Easy programming
  • Class I Div 2/Zone 2 approval and local display

Process operations and sites have several points of temperature that have to be monitored.  Many of these measurements utilize thermocouples. When thermocouples fail or burnout they normally go open circuit due to any number of processes or environmental issues.  

Corrosion Detection/Burnout Indication
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In an effort to catch these thermocouples before they fail, look to the TDZ3/THZ3 Smart HART Dual Input Temperature transmitters that have corrosion detection capability for thermocouples to warn you when the resistance in the thermocouple circuit is stating to increase, that is usually an early indication of a pending element failure.  The THZ3/TDZ3 transmitter family can be HART or DTM programmed and carries worldwide approvals. 

Key Attributes:

  • Advanced sensor diagnostics – Corrosion detection/burnout indication for thermocouples
  • HART or DTM programmable
  • Worldwide hazardous area approvals

Refineries and extraction sites rely on flare stacks to handle unexpected process releases and upsets when they occur. The EPA requires that these VOCs be burned off.  If the flare stack burns out it could lead to volatile compounds being released into the atmosphere and could lead to a costly shutdown. 

Flare Stack Monitoring
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Instead of relying on one T/C and a sophisticated PLC, consider utilizing a 2oo3 voting scheme with SPA2 Site Programmable Alarm Trips.  The SPA2 is approved for installation in Class I Div 2/Zone 2 locations and is push button or PC programmable with quick and easy to use menus.  Each SPA2 has a local display and an optional 4-20mA retransmission.

Key attributes:

  • Simple 2oo3 voting configuration
  • Easy programming
  • Class I Div 2/Zone 2 approval and local display

Upstream and midstream natural gas sites are remote and sometimes do not have the power to create supply air for pneumatic instruments and valves. 

Pipeline remote valve
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When instrument air isn’t available at these locations consider using the IPX2 Current to Pressure Field Transmitter.  While this I/P is usually put in service utilizing air from a compressor, it is also approved for use with natural gas as a supply medium.  The pressurized natural gas pipeline supplies the IPX2 and thus the valve to control the flow.  The IPX2 has explosion proof, flameproof and intrinsic safety approvals and features a removable electronics module for quick calibration and field replacement.

Key attributes:

  • IPX2 approved for natural gas as supply medium
  • Worldwide hazardous area approvals
  • Field removable electronics and reverse output

Refineries require that the water be removed from crude oil before it continues on to first stage processing.  Many water and oil separators are remotely located and typically require an interface level transmitter to enable proper pump control to ensure that only crude oil is forwarded to downstream processing units.  Often these level transmitters are HART capable. (TWO SENTENCES TO CREATE BACKGROUND AND PROBLEM THAT WE SOLVED WITH OUR SOLUTION)

Oil and Gas Upstream and Extraction - Water & Oil Separator Pit

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In these instances, the HIM HART Interface Module can be utilized for separator on/off pump control.  Additionally, the HIM allows additional analog signals to be transmitted from the HART signal which represents additional process variables, allowing the DCS to effectively monitor key parameters of the separator. (TWO SENTENCES  EXPLAINING OUR SOLUTION TO THE PROBLEM THAT INCLUDES PRODUCT’S MAIN WAY IN WHICH IT SOLVED THE PROBLEM – IT IS IMPORTANT TO FULLY UNDERSTAND THE SOLUTION WE PROVIDE “BEFORE” WRITING THE PROBLEM)

Key attributes:

  • HIM provides local on/off control and integral indication
  • Allows additional HART process variables to be transmitted to DCS or remote host
  • Optional MODBUS RTU output

Many facilities sometimes have a block of temperatures that need to be monitored in a central location. 

Water and Wastewater Treatment 05 18 18 14
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You can reduce the expense of installing individual field transmitters by installing DIN rail temperature transmitters in the field, close to the process, and running shielded twisted pair back to the DCS or BPCS. The Class I Div 2/Zone 2 approved THZ3 Smart HART Dual Input Temperature Transmitter is a highly accurate and repeatable DIN rail temperature transmitter with advanced diagnostics. If your control system’s input cards can read HART, you can further reduce your measurement cost per point by bringing two sensors to each THZ3 and reading the PV and SV dynamic HART variables, which represent Sensor 1 and Sensor 2 respectively.

Key Attributes:

  • Class I Div 2/Zone 2 approved DIN version of THZ3
  • Dual input capability may reduce cost per point
  • High ambient operating temperature range of -40 to 85C (-40 to 185F)

Chlorination control is a common requirement at all water and wastewater plants. Complex algorithms and control schemes are required in PLC programs to ensure proper chlorine feed systems are kept in tight control. These PLC systems cannot only be costly but often require constant tuning due to the location of the downstream residual sampling points and chlorine injection locations. 

Water and Wastewater Treatment 05 18 18 4

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When chlorination or dechlorination control is required consider the Nema 4x 555 Chlorination/Dechlorination Controller. This ¼ DIN controller was specifically designed for flow pacing, residual, compound and even dechlorination control.  The program menu and control algorithms have built in dosing level and time delay settings that are a common programming headache in PLCs. 
The controller features a large vacuum fluorescent display with a large five digit upper display and two nine character lines of alphanumerics.

Key Attributes:

  • Includes built in control algorithms for Chlorination/Dechlorination control
  • Easy to program
  • Nema 4x case and large vacuum fluorescent display

The new thinner UL approved Moore Industries ECT-DIN 2-Wire Isolator is now available in a narrow, 15mm aluminum housing and retains the same General and Hazardous area approvals as the rest of the ECT family of isolators. The complete ECT family is rugged and reliable, available with enhanced features delivering reliable signal isolation and conversion solutions for the most demanding locations as well as ambient and noisy installation conditions.

Selecting Smart Temperature Transmitters for General, Hazardous and Process Safety Applications IPP&T (Canada) October, 2019

For many applications, the temperature of a process needs to be monitored by temperature transmitters. Selecting and installing temperature transmitters for an application can be a difficult task, taking into consideration meeting economical requirements of a project while meeting comprehensive safety needs and potentially difficult or remote installation requirements. This article covers what you need to consider when selecting Smart temperature transmitters.

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Get the Benefits of IIoT Without the Heavy Front-end Investment Industrial Ethernet Book (US and Europe) , November 2019

Taking process data from smart HART field devices and sharing it with higher level systems, no longer has to be difficult or expensive. Industrial Ethernet backbones and wireless networks, IIoT HART devices, open industry protocols and ease of programming provides a quick and seamless way to share process data.

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When You Need to Pass HART Data, Use Rugged and Reliable HART Isolators from Moore Industries. Instrumentation (UK) November, 2019

Prevent and solve common and costly problems that plague many of today’s smart process loops while reliably passing along valuable HART process and diagnostic data from process instruments and transmitters by using highly rugged and economical HART® isolators. 

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Dual Input Temperature Allows for Uninterrupted Process Monitoring, Process Industry Informer (UK and Europe) June, 2019

Temperature sensor failure can wreak havoc on processes where maintaining temperature is critical and monitoring must be continuous. Whether it’s a runaway temperature that spoils a batch or a process interruption when an alarm shuts down the process due to a sensor failure, you lose time and money. Learn how you can solve these issues saving both time and money by using dual input temperature transmitters.

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HART via MODBUS to optimize asset-management-system processes SmartIndustry March, 2019

Over the last few decades, the introduction of industrial Ethernet and wireless networks in process manufacturing plants and automation facilities has meant that data exchange within a facility and even throughout global corporate networks is becoming commonplace. The challenge for legacy plants is to find inexpensive and convenient ways to take advantage of the data already available in existing field devices. This article discusses how HART interface devices with open industry protocols and ease of programming provide a quick and seamless way to share process data.

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NORTH HILLS, Calif.—Sep. 12, 2019—Our industry lost a great man and pioneer on September 6th, 2019.  Leonard W. Moore (Len) who was founder and owner of Moore Industries-International, Inc. (www.miinet.com) passed at the age of 85. Len was born November 26th, 1933 in Hazelton, Iowa where he attended elementary through high school. At the age of 16 he graduated high school and then attended Iowa State University where he obtained a BS in Electrical Engineering.

After graduating college Len entered the Army in 1953 as a weapons guidance specialist and spent time at Fort Sill, OK and Fort Bliss, TX. He then served time in Japan training and teaching soldiers how to operate, calibrate and repair various guidance and artillery weapon systems. It was here where Len realized he had a passion for instruments and control circuits. After his tour in Japan, he left the Army and returned home to Iowa.

Leonard W Moore

In 1958, newly married to wife Martha Moore and eager to start his career, he took a job with Hughes Aircraft in El Segundo, CA.  With one car and only a few suitcases to their name, Len and his wife packed up and headed west to start their new life. After a few years with Hughes and a few more engineering and automation jobs, Len made a bold decision to do things his own way – in 1968 he founded Moore Industries-International, Inc. in North Hills, CA.  Starting out in a small office with one employee and a very small budget, Len set out to design the most rugged industrial instrument solutions that he knew the industry needed.  He used to say that at Moore Industries “we are an engineering company that solves customer’s problems by manufacturing bulletproof solutions.”

Starting with one signal isolating/converting instrument, the SCT Signal Converter and Isolator, Len and his “troops” (the term that he used for the company’s employees) went on to design, build and support more than 225 different products that isolate, protect, convert, alarm, monitor, control and interface with any industrial or automation control and monitoring system. Len often said, “the best compliment we can get from our customers is that they forgot about our products or solutions because they performed so well that they just plain forgot they were ever installed.” This rugged M1 Tank design mentality, which he mandated, can be seen in most of the company’s products that are enveloped in solid aluminum cases instead of fragile plastic or polycarbonate housings.

More than 50 years after its inception, Moore Industries’ world headquarters is still prospering and remains in North Hills, CA. The company continues to manufacture 100% of its products at this USA location, something Len insisted upon.  With two acquisitions, more than 19 industry associated patents, 200 employees and remote offices located in the United Kingdom, The Netherlands, Belgium, Australia and China, the company continues to engineer, design, manufacture and support existing and new products for worldwide process control and automation customers. 

While Len had a passion for his company and its employees, he lived a full life outside of the company too.  Len was an accomplished race car driver spending time in racing schools, competing on the Trans Am Race Circuit, and even sponsoring an Indy Series car during the 1980’s.  Flying was also a hobby and interest of Len’s.  Although he had hundreds of hours under his belt flying right seat during work trips in the company’s Commander airplane, it wasn’t until 2005 that Len finally went ahead and formally got his pilot’s license.  During this time, he had another side project going on:  restoring, and later flying, a 1946 single engine Ercoupe in his hangar to museum-like condition with World War II Army Air Corps colors.  Len used to say, “this is the world’s most expensive Ercoupe”, which is no surprise because he was an absolute perfectionist. He later donated this plane to the Palm Springs Air Museum.

In 2009 Len was inducted into the ISA’s revered group of Honorary Members - individuals whose support of, and/or contributions to, the advancement of the arts and sciences of instrumentation, systems, and automation are deserving of special recognition.  Len was also a Professional Engineer, had a private contractor’s license and was, of course, a pioneer and cornerstone for our industry.

Len is survived by his three sons: Tony and his companion Sonnie, Nick, and Chris and his wife Deanna; his grandsons Nick, Matthew, Justin and Christopher; and his longtime companion Christine Hulfish.

To a smart, devoted and compassionate man with a quick wit and great sense of humor who left a long and impressive legacy - Godspeed Len, we will miss you greatly.

About Moore Industries-International, Inc.:

 

Based in North Hills, CA, Moore Industries is a world leader in the design and manufacture of rail, panel and field instruments for industrial process control and monitoring, system integration and factory automation. The company has direct sales offices in the United States and additional strategic worldwide locations in Australia, Belgium, the Netherlands, the People's Republic of China and the United Kingdom. The company serves a variety of industries such as chemical and petrochemical; power generation and transmission; petroleum extraction, refining and transport; pulp and paper; food and beverage; mining and metal refining; pharmaceuticals and biotechnology; industrial machinery and equipment; water and wastewater; and environmental and pollution monitoring. 

Many water and wastewater treatment facilities need 4-20mA signals from field transmitters and analyzers to be shared with their BPCS (Basic Process Control System) and alternate monitoring systems or SCADA system. Using area isolation, also known as signal splitting, by connecting the secondary system on the secondary side of the isolator, failure of this loop does not impact the primary loop to the BPCS. When connecting these secondary systems, such as a SCADA system, users can rest assured that if it fails or is removed, the primary host or control system will continue to receive the uninterrupted process signal. 

By using a narrow isolator you can double the isolator count in the same space. This is ideal for utilizing existing field mounted cabinets. When the cabinet needs to be located in an area with extreme ambient temperatures and the location is a hazardous area where climate control of the cabinet is problematic, a narrow isolator with necessary approvals that can withstand the extreme environment is needed.

ECT Skinny Haz Location Cabinet

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The narrow 15mm ECT-DIN signal isolator and converter with 4-20mA, 1-5V and 0-10V inputs and 4-20mA output allows more isolators to fit in cabinets and field enclosures where installation space is a premium. Being UL Approved for General and Hazardous areas, and having the same RFI/EMI protection and -40°C to 85°C operating temperature range as the rest of the ECT family of isolators, this narrow and rugged isolator can be installed in hazardous locations and does not require installation in cooled or climate controlled environments making it perfect for more extreme locations.

Many process facilities need 4-20mA signals from field transmitters and analyzers to be shared with their BPCS (Basic Process Control System) and alternate monitoring systems or backup PLCs.  But wiring these three elements in series breaks loop integrity and can cause problems when the secondary or backup system fails or is disconnected. Using area isolation, also known as signal splitting, by connecting the secondary system on the secondary side of the isolator, failure of this loop does not impact the primary loop to the BPCS. They can connect these secondary systems, such as a backup PLC, and ensure that if it fails or is removed, the primary host or control system will continue to receive the uninterrupted process signal.  

By using a narrow isolator you can double the isolator count in the same space. This is ideal for utilizing existing field mounted cabinets. When the cabinet needs to be located in an area with extreme ambient temperatures and the location is a hazardous area where climate control of the cabinet is problematic, a narrow isolator with necessary approvals that can withstand the extreme environment is needed.

ECT Skinny Haz Location Cabinet industries

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The narrow 15mm ECT-DIN signal isolator and converter with 4-20mA, 1-5V and 0-10V inputs and 4-20mA output allows more isolators to fit in cabinets and field enclosures where installation space is a premium. Being UL Approved for General and Hazardous areas, and having the same RFI/EMI protection and -40°C to 85°C operating temperature range as the rest of the ECT family of isolators, this narrow and rugged isolator can be installed in hazardous locations and does not require installation in cooled or climate controlled environments making it perfect for more extreme locations.

Many food, beverage and pharmaceutical process facilities need 4-20mA signals from field transmitters and analyzers to be shared with their BPCS (Basic Process Control System) and alternate monitoring systems or chart recorder. But wiring these three elements in series breaks loop integrity and can cause problems when the secondary or backup system fails or is disconnected. Using area isolation, also known as signal splitting, by connecting the secondary system on the secondary side of the isolator, failure of this loop does not impact the primary loop to the BPCS. They can connect these secondary systems, such as a chart recorder, and ensure that if it fails or is removed, the primary host or control system will continue to receive the uninterrupted process signal.  

By using a narrow isolator you can double the isolator count in the same space. This is ideal for utilizing existing field mounted cabinets. When the cabinet needs to be located in an area with extreme ambient temperatures and the location is a hazardous area where climate control of the cabinet is problematic, a narrow isolator with necessary approvals that can withstand the extreme environment is needed.

ECT Skinny Haz Location Cabinet

Download the PDF file

The narrow 15mm ECT-DIN signal isolator and converter with 4-20mA, 1-5V and 0-10V inputs and 4-20mA output allows more isolators to fit in cabinets and field enclosures where installation space is a premium. Being UL Approved for General and Hazardous areas, and having the same RFI/EMI protection and -40°C to 85°C operating temperature range as the rest of the ECT family of isolators, this narrow and rugged isolator can be installed in hazardous locations and does not require installation in cooled or climate controlled environments making it perfect for more extreme locations.

The ability to use existing industrial Ethernet and wireless networks in process manufacturing plants and automation facilities has made data exchange within a facility and even throughout global corporate networks easier than ever. Process and diagnostics data from smart HART digital field instruments is being shared with mid and higher-level control, asset management and data information systems without having to upgrade expensive process control systems.

At Moore Industries, we are seeing numerous customers using the HES HART to Ethernet Gateway System to collect and transmit valuable smart HART device data to these higher-level systems over Ethernet via MODBUS/TCP for predictive analysis and control decision-making.

In a recent application, a customer needed to control two valves that had Siemens smart HART positioners installed and had a further requirement to communicate actual valve position over Ethernet using MODBUS/TCP to their higher-level systems.

Stream Precise Positioning Data from Electronic Valve Positioners

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Originally the customer wanted to use the Moore Industries model 535 or 545 PID Controllers to control the two valves in order to balance and/or limit each valve’s travel to maintain final pressure through the system, but they realized that the controller’s communication capability did not support Modbus/TCP as their DCS and Historian required.

Moreover, the higher-level monitoring systems wanted to monitor and record where actual stem positions currently were, not where the valve controller was driving them to via the 4-20mA signal.  This could only be obtained by reading the HART data from the smart positioners.

The HES 4-channel model was utilized to pick up the actual stem position HART data from the smart positioners and send it to the higher-level systems – no longer requiring the valve controller to communicate the CV (Controlled Variable), or desired stem position, output. The HES was an effective and economical solution that enabled the customer to take advantage of existing HART data from the positioners and share that critical data with their higher-level systems on their existing Ethernet infrastructure. 

 

Accelerate your HART data. Timely knowledge about your process enables better decisions and faster preventive action. Now you can get the process detail that you need from your Smart HART devices to MODBUS/TCP and HART-IP based monitoring and control systems at the speed of Ethernet with the HES HART to Ethernet Gateway System from Moore Industries.

Process facilities have a significant investment in the BPCS (Basic Process Control System) and upgrading with new HART capable input cards or a new control system in order to get HART data from newer smart HART devices is often cost-prohibitive. But they still need to get HART data from key devices to optimize their process. Plus, with expanding analytics capabilities of higher-level systems and the spreading adoption of IIOT, a way is needed to get that valuable data where it can be factored into predictive analytics.

IIOT Monitor Valve Positioners over Ethernet

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In this example the BPCS MODBUS/TCP host for the process does not have any smart HART input cards. This existing point-to-point 4-20mA process loop uses a four-channel HES HART to Ethernet Gateway System to extract valuable PV data and diagnostics from HART smart valve positioners and reports it to the BPCS over Ethernet using MODBUS/TCP or HART-IP, without any BPCS upgrades. This can help provide early warning for critical valves before they fall out of performance specifications or fail. Additionally, any remote computer connected to the corporate network can view any data such as diagnostics and process variables gathered by the HES via a standard web browser. 

Key attributes

HES can poll for:

Process facilities have a significant investment in the BPCS (Basic Process Control System) and upgrading with new HART capable input cards or a new control system in order to get HART data from newer smart HART devices is often cost-prohibitive. But they still need to get HART data from key devices to optimize their process. Plus, with expanding analytics capabilities of higher-level systems and the spreading adoption of IIoT, a way is needed to get that valuable data where it can be factored into predictive analytics.

HES as a HART Mux Multiplexer for Valve Positioners

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In this example the BPCS MODBUS/TCP host for the process does not have any smart HART input cards. This existing point-to-point 4-20mA process loop uses a four-channel HES HART to Ethernet Gateway System to extract valuable PV data and diagnostics from HART smart valve positioners, and reports it to the BPCS over Ethernet using MODBUS/TCP or HART-IP, without any BPCS upgrades. This can help provide early warning for critical valves before they fall out of performance specifications or fail. Additionally, any remote computer connected to the corporate network can view any data such as diagnostics and process variables gathered by the HES via a standard web browser. 

Key attributes

HES can poll for:

  • Dynamic Variables (PV, SV, TV and QV)
  • 128 Device Variables from HART 7 devices
  • 25 Bytes of diagnostic data (Command 48) in addition to the above variables
  • See this product in the online Catalog

Process facilities have a significant investment in the BPCS (Basic Process Control System) and upgrading with new HART capable input cards or a new control system in order to get HART data from newer smart HART devices is often cost-prohibitive. But they still need to get HART data from key devices to optimize their process. Plus, with expanding analytics capabilities of higher-level systems and the spreading adoption of IIoT, a way is needed to get that valuable data where it can be factored into predictive analytics.

HES as a HART Mux Multiplexer

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In this example the MODBUS/TCP capable BPCS does not have any smart HART input cards. The four existing point-to-point 4-20mA process loops connect to a four-channel HES HART to Ethernet Gateway System that extracts HART data from the field transmitters, converts it to MODBUS/TCP and reports it to the BPCS over Ethernet, without any BPCS upgrades. Additionally, any remote computer connected to the corporate network can view any data such as diagnostics and process variables gathered by the HES via a standard web browser.

Key attributes

HES can poll for:

  • Dynamic Variables (PV, SV, TV and QV)
  • 128 Device Variables from HART 7 devices
  • 25 Bytes of diagnostic data (Command 48) in addition to the above variables
  • See this product in the online Catalog

Process facilities in most industries have multitudes of HART devices monitoring processes throughout the plant. The challenge is getting all of the HART data from those instruments to the control systems and higher-level systems for predictive analytics while controlling costs and without running more wires.

4 Channel HART To Ethernet Gateway

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A four channel HART to Ethernet gateway is a perfect device to serve as a remote HART I/O interface to MODBUS/TCP hosts by multidropping up to 16 HART devices per channel, 64 devices total. For maximum density, the HES HART to Ethernet Gateway System can be used to gather hundreds of HART variables from multiple devices and send over Ethernet. If diagnostic bits and bytes are included, the data points reach into the thousands for each HES. Additionally, any remote computer connected to the corporate network can view any data such as diagnostics and process variables gathered by the HES via a standard web browser. 

Key attributes

HES can poll for:

  • Dynamic Variables (PV, SV, TV and QV)
  • 128 Device Variables from HART 7 devices
  • 25 Bytes of diagnostic data (Command 48) in addition to the above variables
  • See this product in the Online Catalog

Process facilities have a significant investment in the BPCS (Basic Process Control System) and upgrading with new HART capable input cards or a new control system in order to get HART data from newer smart HART devices is often cost-prohibitive. But they still need to get HART data from key devices to optimize their process. Plus, with expanding analytics capabilities of higher-level systems and the spreading adoption of IIoT, a way is needed to get that valuable data where it can be factored into predictive analytics.

Single channel HART to Ethernet gateway

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In this example the BPCS MODBUS/TCP host for the process does not have any smart HART input cards. This existing point-to-point 4-20mA process loop uses a single channel HES HART to Ethernet Gateway System to extract HART data from a smart HART flowmeter, converts it to MODBUS/TCP and reports it to the BPCS over Ethernet, without any BPCS upgrades. Additionally, any remote computer connected to the corporate network can view any data such as diagnostics and process variables gathered by the HES via a standard web browser. 

Key attributes:

HES can poll for:

  • Dynamic Variables (PV, SV, TV and QV)
  • 128 Device Variables from HART 7 devices
  • 25 Bytes of diagnostic data (Command 48) in addition to the above variables
  • See this product in the Online Catalog

Sometimes there are temperature measurements that require advanced functions like differential, averaging or even high select capability.

Dual Input Capabilities for Temperature Measurements

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Rather than running signal wires all the way back to a PLC or DCS to perform those functions, consider the THZ3/TDZ3 Smart HART Dual Input temperature transmitters.  This family of transmitters can accept dual sensor inputs and can perform sensor backup/failover, averaging, differential, absolute differential, high select and low select functions. The THZ3/TDZ3 transmitter family can be HART or DTM programmed and carries worldwide approvals. 

Key Attributes:

  • Advanced measurement functions with dual sensor input
  • HART or DTM programmable
  • Worldwide hazardous area approvals
  • See THZ3/TDZ3 in our Catalog

Every oil and gas site uses a vast array of different length solid sheathed, spring loaded RTDs and thermocouples.  Stocking these various lengths for every temperature measurement point can be very costly and time consuming.

the WORM – Field Cuttable Temperature Sensor

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To lower inventory needs and increase your quality of temperature measurements, consider the WORM Flexible Temperature Sensor that comes in just about every type of RTD and Thermocouple.  With a quick measurement and a simple in-field trim-to-length, the WORM handles nearly every thermowell assembly.  The smaller mass of the WORM yields a 13% faster response time, minimizes ambient temperature effects and with its proprietary potting offers better resilience to high vibration environments, which is a common cause of failure with RTDs.  You can buy a single WORM, pack or three or save more money by ordering 10 in a can of WORMS.

Key Attributes:

  • Flexible WORM sensor fits almost any thermowell length
  • 13% faster response time
  • More resilient in high vibration applications that fixed-length solid sheathed RTDs
  • See this product in the Online Catalog

Natural gas pipelines are under high pressure but not all sections of the pipeline are rated the same. Specifically, there is an area called the Specification Break which is defined as an area where high-pressure piping transitions to a lower pressure rated section.  Those areas are particularly vulnerable to ruptures or fissures and need to be monitored.

Over Pressure Protection for Pipeline Spec Break

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Rather than buying an expensive and complex safety PLC, look to the STA Functional Safety Trip Alarm as your Safety Instrumented System logic solver.  You can utilize three STAs in a 2oo3 voting scheme to initiate an emergency shutdown when a rupture or leak occurs at the Specification Break.  Similarly, you could do the same for the temperature.  The STA is SIL 2/3 capable, approved by exida and rated Class I Div 2/Zone 2.

Key attributes:

Tank overfill protection is required for all tanks holding hydrocarbons. Often this layer of protection is a Safety Instrumented System (SIS) that includes a level transmitter, logic solver and a shutdown valve.  

Oil and Gas Upstream and Extraction 6

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Rather than a complex and expensive safety PLC, look to the STA Functional Safety Trip Alarm as your Safety Instrumented System logic solver for tank overfill protection. The STA is simple to program and has an auxiliary analog output for retransmission to the local RTU.   The STA is SIL 2/3 capable, approved by exida and rated Class I Div 2/Zone 2.


Key attributes: 

  • SIL 2/3 capable
  • Easy programming
  • Class I Div 2/Zone 2 approval and local display

Upstream gas wellheads can experience extremely high pressure and surges. In order to protect personnel and equipment wellhead casing pressure is often monitored in case there is a situation where the wellhead needs to be shutdown. Traditionally simple pressure switches were used but today companies are required to implement proper safety systems.

Wellhead Gas Pressure - IEC61508 Certified SIL 2 Trip with AO

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When required to add layers of protection at the wellhead site, consider the STA Functional Safety Trip Alarm as your Safety Instrumented System logic solver when an overpressure situation occurs. The STA is simple to program and has an auxiliary analog output for retransmission to the local RTU.   The STA is SIL 2/3 capable, approved by exida and rated Class I Div 2/Zone 2.


Key attributes

  • SIL 2/3 capable
  • Easy programming
  • Class I Div 2/Zone 2 approval and local display

Coal seam gas that is extracted from the ground is full of water and other non-hydrocarbon compounds. Before the gas is sent to the storage well it has to go through a separator. These separators have to run at specific pressures.

Coal Seam Gas Wellhead Separator Over-Pressure Protection

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Protect personnel and the separator with the STA Functional Safety Trip Alarm as your Safety Instrumented System logic solver by monitoring the separator pressure and turning off the water pump when an overpressure situation occurs. 

The STA is simple to program and has an auxiliary analog output for retransmission to the local RTU. The STA is SIL 2/3 capable, approved by exida and rated Class I Div 2/Zone 2.

Key attributes:

  • SIL 2/3 capable
  • Easy programming
  • Class I Div 2/Zone 2 approval and local display

SRM SST SSX horizontal PPstudy by the ARC Advisory Group in 2011 showed that 46 percent of all field devices installed worldwide communicate using the HART protocol. This is more than all fieldbus devices, proprietary protocols and 4-20mA (analog/non-smart) combined. There’s a good chance that you are have HART-enabled devices in use at your plant or off-site location. The question is: are you getting the most from HART?

Moore Industries has a range of products designed to help end users access the powerful information available through smart HART instrument systems. These products accept and "read" the HART digital protocol signal that rides on the 4-20mA wires of a smart HART multivariable transmitter or valve. Some of our HART products provide additional benefits such as isolating, splitting, converting or “breaking out” HART signals.

Here’s a look at our key HART products:

SSX and SST Safety Series Isolators and Splitters: Part of Moore Industries’ FS Functional Safety Series, the exida-approved, SIL 3 capable 2-wire (loop powered) SSX and 4-wire (line/mains powered) SST Safety Isolators and Splitters provide isolation and signal conversion for your SIS (Safety Instrumented System) needs. These units protect and enhance loops and also pass valuable HART data from the field transmitter to host systems and vice-versa. In addition, the SST Splitter model takes the input from one of your process signals and creates two identical, completely isolated outputs to two separate monitoring or control devices.

HIMHIM HART Interface Module: The HIM unlocks the full potential of new and in-place smart HART multivariable transmitters and valves. It allows up to three additional analog process variable measurements from a smart device with no additional process penetrations or wiring. It provides additional analog signals proportional to a multivariable transmitter’s primary, second, third or fourth variables, or to user-selectable valve parameters such as stem position. It also provides High/Low process and loop diagnostic alarms.

HCS HART Concentrator System: The HCS converts a HART digital signal to a serial (RS-485 or RS-232) MODBUS RTU communication protocol. This allows HART transmitters and valves to interface directly with MODBUS-based monitoring and control systems. It operates in point-to-point HART mode or up to 16 HART instruments can digitally communicate on the same wires in a digital multidrop HART network. It can monitor primary and non-primary variables along with HART instrument diagnostics.

You can see an example of how the HCS is used in remote natural gas settings with our online video.

These are just a few of our most popular HART products. For more information, check out the Smart HART Loop Monitors and Interfaces section of our website.

 

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sales teamvery two years, our International Sales team comes to Moore Industries our worldwide headquarters for a week of meetings. It's a great opportunity for the team to share ideas and plan their sales activities in the future. While the meetings are hard work, there are some opportunities to unwind. Moore Industries hosts a dinner for the team and there is an off-site activity to bring the team together. This year it was exciting go-kart racing followed by billiards.

Here's a look at some of the photos from the week.

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Hazardex show

On February 27th and 28th MIE (Moore Industries-Europe Inc.) will attend Hazardex 2019 at the Holiday Inn Hotel in Runcorn, Cheshire, UK. Hazardex is a journal, website and Conference that provides up-to-date industry information on challenges and compliance. This annual event aims to strengthen and expand the community in the process industry that looks to Hazardex for news and information on hazardous areas and Functional Safety issues. MIE will be exhibiting intrinsically-safe, explosion proof and functional safety products such as SPA2ISTHZ3STASTZSSTSRM along with Moore Industries new HES, HART to Ethernet Gateway System

 

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IPT2 Q:  A field tech told me he installed an IPT2/4-20MA/3-15PSIG/20PSIG/-FA1 [DIN] unit.  In the product bulletin I don't see a purpose for the trailing "2" in the model name, and I don't see an explanation for -FA1.

A: The “2” in IPT2 indicates that it is the successor to the older IPT. It is a direct replacement with same form/fit/function with improved performance.

The -FA1 option code is explained in table 2 on page 3 of the data sheet (click the link to open the download page).

It means that it has a mounting block for installation of the unit on DIN rail.  It also designates that the supply and outlet ports are on the bottom of the mounting block, the electrical signal test jacks, and electrical connections are on the front face, and that there is no pneumatic test jack.

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SPA ppQ: We are considering ordering the Moore Industries SPA/0-100mV/2 PRG/U/-SOL [DIN]. Can we power it using 24VDC? If so, what is the power consumption and how do we terminate? Also, can you please confirm whether this unit is Class 1 Div2, group A,B,C,D?

A: The SPA can be powered with 24VDC. It accepts any source voltage in the ranges of 22-300Vdc or 90-260Vac. Power Consumption is 2-4W, nominal; 6W, maximum.

If you specify the -HS option (hermetically sealed relays) then it is approved for Class 1 Division 2 locations when installed in an enclosure that provides sufficient mechanical and environmental protection. Usually, a NEMA 4 rated box will serve. See page 1 of the data sheet (click the link to open the download page).

The sample model number with -HS option and with a NEMA 4 enclosure is:
SPA/0-120MV/2PRG/U/-SOL-HS [R3H]. 

The –SOL option in this model number indicates a specially engineered SPA used to monitor the health of solenoid valve coils.

 

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Q: What are some ways to improve the long-term stability of my RTD temperature measurement?

 

A: There's no question that the first step in improving the overall quality and long-term stability of your temperature readouts is to use a Class A, 4-wire RTD. Lead wire imbalances are a major cause of instability during the measurement process. A single ohm of imbalance in a three wire, platinum .00385 alpha, 100 ohm RTD can produce as much as 2.5°C of error in a measurement. By adding a fourth lead wire, you eliminate potential errors in measurements created by resistance imbalances between leads. 4-wire RTDs are no longer just for special uses, and they aren't cost-prohibitive. In fact, in many cases they are more cost-effective than using traditional 3-wire RTDs.

4 wire RTD

 

 

Another way to improve long-term stability is to make sure that your RTDs have been thermally aged. This process involves placing RTDs into a continual cycle of temperature extremes that season the RTD and even help extend its measurement life. The sensors that we use in high-accuracy applications have been temperature cycled from 0°C to 600°C for 1,000 hours, making them virtually drift-free for the next five to 10 years.

See more about Moore Industries' Temperature transmitters and temperature solutions.

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ehelp spa2Q: For the STA 4-Wire SIL 2 and SIL 3 Compliant Programmable Current/Voltage and RTD/Thermocouple Safety Trip Alarms, can the process alarm relays be configured as Failsafe?  Can the process relay output of the SPA2-TRPRG be configured Failsafe?

A: The output relays of the STA are configured only as Failsafe.  For example, the coils are de-energized in the alarm condition or when there is a loss in power.  For systematic integrity up to SIL 3 and for random integrity up to SIL 2, the STA is also exida certified 61508:2010.  This means that an STA is approved for single use in Safety Instrumented Systems (SIS) up to SIL 2 and in redundant architectures (1oo2, 2oo3, etc.) up to SIL 3.

The output relays of other alarms that we offer such as the SPA2 can be configured either as Failsafe or Non-Failsafe.

Download the SPA2 or STA data sheet for more details.

SPA2 Low Level Q: Does your SPA2 have a SIL 2 rating?

A: The SPA2 can be used in safety instrumented systems (SIS) as long as the appropriate safety-related data and restrictions in use are reviewed and followed by a competent safety practitioner. We have a FMEDA (Failure Modes, Effects and Diagnostics Analysis) report that provides this data for the SPA2, and is available upon request.

We also offer the STA Functional Safety Limit Alarm Trip, which is expressly designed for safety related applications and has third party certification (exida) per IEC 61508:2010 for systematic integrity up to SIL 3 and for random integrity up to SIL 2.

The exida certified FMEDA data can be provided and used by a competent functional safety practitioner to calculate the required PFDavg and determine the SPA2s or STAs SIL capability and overall suitability in your Safety Instrumented Systems (SIS). 

Do you want more information? Download the data sheet. Or visit the catalog.

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thz3 tdz3Q: I am looking for a signal conditioner that has multiple inputs (RTD) that can be averaged on one mA output.  What do you recommend?

A: First determine how many RTDs you need to average, the number of wires (2-wire, 3-wire, or 4-wire), and are the cable lengths the same for each RTD? Then we can help you determine which product will fulfill your specific needs.

Moore Industries has several products that can handle multiple RTD inputs and provide a calculated average output. 

Both field-mount and Din-mount models are offered.  The THZ3/TDZ3 models handle two RTD inputs while the SPT, MDS and NCS handle three or more RTD inputs.  If you have an application that involves Safety Instrumented Systems (SIS), the STZ transmitter family can be used.

The THZ3 is a smart HART two-wire, output loop powered transmitter that comes in a hockey puck configuration for field mount applications or in a DIN rail mount package for cabinet installations.  The TDZ3 is a field mount unit with an integral display.  Both units offer the ability to output a 4-20mA signal that represents the average of the RTD inputs.

SPT ppThe SPT accepts T/C, RTD, millivolt, or ohms input in different ranges, sensor types, and connection schemes.  The SPT has a simple menu system and LCD screen for easy setup and calibration, and all settings are stored in non-volatile memory, protecting them from power loss.

The I/O Equation Station Multifunction Distributed I/O System (MDS) is a four-wire module that can average up to 4 RTDs.  The number of wires per RTD depends on the number of RTDs that can be connected. 

The Net Concentrator System (NCS) is an expandable I/O system that consists of input and output modules that  can be configured to accept any number of RTD inputs to calculate an average output. The NCS can be programmed to handle a wide range of signal input and output including current, voltage, discreet, relay, RTD, thermocouple, resistance, and potentiometer with an operating range of -40°C to +85°C.

 

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STA EhelpQ: We do not have sufficient PLC digital output spares to perform a Manual Reset of the three installed safety temperature controllers. We are going to remove the alarm latching on both limits and faults on our STA Functional Safety Alarm Trip. The Manual Reset radio button stays active in the STA configuration software. Will the latches clear after we are outside the dead band limits? 

A: The radio buttons selected in the Manual Reset rectangle are irrelevant if you have not checked any of the Latching check boxes in the Display Alarms tab. Therefore, if latching is unchecked, the alarm state will reset once normal conditions exist after a brief event.

When using the configuration software, settings are downloaded to the instrument in the form of a Configuration File and stored in the instrument’s memory. You can save a backup copy of the file on your PC hard drive. The STA communicates with the PC through an RS-232 connection to the PC’s serial port or optional USB Communications Cable. Learn more about the STA Functional Safety Alarm Trip.

Wet WellProblem: Municipalities often have several wet well locations around a city that pump waste from low lying areas up to main sewage veins that feed waste treatment plants.  Level instruments monitor the wet well level and controllers then engage the grinder pumps.  Since wet wells contain waste, volatile gasses such as methane require that these level instruments be rated for use in Class I, Div 1 environments.

Solution: When IS (Intrinsic Safety) is chosen as the method of protection, a separate IS barrier is required for each level transmitter that is wired to the pump controller. The SPA2IS Alarm includes a built in IS barrier for the level instrument located in the wet well.  This means that the separate IS barrier does not have to be purchased, installed and maintained.  The SPA2IS has four alarms, each configurable with 0-100% deadband, which makes it an ideal fit for a wet well level controller.

SPA2IS Wet Well Diagram

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whitepapersMake sure you check out the Technical White Papers section of the Moore Industries website. It's a great resource to find out more information about Moore Industries and our products. The white papers available for download cover a variety of topics including:

  • Alarm Trips and Logic Solvers
  • Intrinsic Safety
  • Functional Safety
  • Process Control and Distributed I/O Networks
  • Temperature Measurement
  • HART and Fieldbus

These are just a few of the topics covered in our white papers. Get technical information on the installation and use of Moore Industries products or read about how customers are using Moore Industries' instrumentation in real world settings. Our White Papers are free to download and just a click away.

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HCS norails ppQ. What are the advantages and limitations of HART protocol or an instrument with MODBUS communication embedded? How many instruments can the HCS interface in the same loop? Are we able to read/write the five instruments at the same time using HART?

A. Today, a major advantage that HART and MODBUS RTU possess is industry- wide acceptance by users and manufacturers. HART-enabled transmitters, valve positioners, flowmeters, and other smart devices superimpose a digital signal upon their 4-20mA process signal. Combining digital communications with the 4-20mA DC signal provides flexibility of application for process control instrumentation and accommodates multiple variables and device self-diagnostics. HART field transmitters measure process parameters as well as generating a 4-20mA signal used for process control by a DCS, PLC or some other control system and are easily configurable or diagnosed with a HART handheld communicator (HHC). Several digital control system vendors offer a HART based systems for predictive maintenance that take advantage of the HART devices’ self-diagnostic capability. The disadvantage to HART is that the digital signal is slow. A maximum of 16 HART devices can be connected on a HART multi-drop loop. In that case, the analog signal is fixed to a value of 4mA.

The advantages of MODBUS RTU are that it is strictly digital (RS485) and it’s relatively fast but it does require at least two wires for signal and two wires for power; unlike HART that has signal and power over the same two wires. A significant number of MODBUS RTU addresses can be connected in multi-drop on the signal RS485 data link. 

The HART Concentrator System HART-to-MODBUS RTU Converter (4-Wire) HCS is a HART Master (either the primary of the secondary master), and sends queries to the HART device(s). The HCS can communicate with up to 16 devices in multi-drop mode on one twisted pair loop. The collected data is stored in MODBUS RTU registers in the HCS. On the MODBUS side, the HCS is a MODBUS RTU Slave, so it responds to queries from a MODBUS RTU Master. The MODBUS RTU Master can only read data from the HCS. It cannot write data to the HCS with the intent to change settings in the HART device(s).

In a HART multi-drop loop, each instrument will have its own unique HART address. HART does not allow simultaneous communication to multiple instruments in a multi-drop loop. Instead a HART master or host has to poll each HART slave’s unique address and communicates with one HART device at a time. Moore Industries’ HCS HART Concentrator System converts a HART digital signal to a serial (RS-485 or RS-232) MODBUS RTU communication protocol. This allows HART transmitters and valves to interface directly with MODBUS-based monitoring and control systems. In point-to-point HART mode, the HCS concentrator system is set to monitor a single instrument. Wiring details for both single loop and multi-drop are shown in the HCS. In a multi-drop, the HCS sends queries and receives data from each HART instrument in turn. This follows the defined HART protocol.

Find out more about the HCS.

 

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WORM photoOne of our customers uses ethylene for its process feed and has installed a new ethylene terminal with a 18m3 storage tank. It was necessary to install a new pipeline network to connect the terminal to production plants, other existing pipelines, and to neighboring companies using ethylene. For safety reasons, the pipeline was buried 1.5 meters deep.

To monitor temperatures across the pipeline, 16 temperature sensors needed to be installed at various points. Because the integrity of the pipeline was critical for safety reasons, there could be no welding or other intrusions into the pipe. This led to using skin sensors that meet ATEX Explosion-Proof requirements to take the temperature measurements.

A typical solution is a 6mm-diameter mineral-insulated RTD or T/C sensor with a skin path that is strapped to the underground pipe while a cable travels to the surface where the head is installed. The problem with this design is if the sensor fails, it requires expensive digging near the underground pipeline to replace. A better solution uses a pipe skin mounting block strapped onto the buried pipe, a 1/2"-diameter stainless steel pipe that reaches the surface and a transmitter directly mounted onto the pipe. This allows a sensor to be replaced without costly digging but also means that a sensor needs a sensitive tip. 

A perfect choice for this application is the WORM Flexible Sensors for Thermowell Temperature Assemblies. It provides accurate, fast readings and its flexible design with a universal length allows it to reach almost any spot. The WORM’s unique flexible design allows installation quickly and it delivers step response times 13% faster than standard sensors. The installation kit provides parts for three different installation options. The WORM can be purchased in economical 10 packs. Check out the WORM data sheet for more details.

Want to learn more? Get the product data sheets on other products such as THZ3 & TDZ3 Dual Input Smart HART Temperature Transmitter, THZ DH & WL Smart HART and WirelessHART Temperature Transmitter (2-Wire), and BULLET WirelessHART Adapter.

 

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ECTQ. I have an application that requires an analog splitter. The single input signal to the splitter comes from a transducer, and the transducer requires loop power. The two outputs are going to an analog monitoring card on a PLC, which provides power to the connected 4-20mA signal signals. Is the ECT what I need?

A. If you need a device with two outputs and with output loop power, the MIX would be a good choice. However, this model does not provide loop voltage to the input. It is a dual channel isolator so you would connect the input signal in series to the two input channels. MIX 2 and 4-channel models draw operating power from the loop output side, where power is typically made available by the receiving device, such as a DCS or PLC.

The ECT “Splitter” on the other hand provides loop voltage to the transducer, and it also provides the voltage to the two output loops. It requires a power source separate from the output signals.

You can specify either 24DC or 117AC for the separate power input. If the outputs must be compatible with a control system input card that is providing loop voltage then the EP option for the ECT modifies them to be passive. However, a separate power source is still required. The ECT offers Superior signal isolation (up to 1500Vrms). An ECT with the following model number would meet your application requirements: ECT/4-20MA/4-20MA/24VDC/-EP [DIN]

Quality and industrial strength protection stops ground loops, motor noise, and other electrical interference from affecting process signals. The ECT offers RFI/EMI protection against the unpredictable, harmful effects of radio frequency and electromagnetic interference. There is even a –RF option for enhanced protection in especially noisy environments.

Please visit our Interface Solution Download Center for more information on the MIX or the ECT line of products.

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