Rugged instrumentation for reliable measurement and control

Applications By Industry

Problem: We have a couple of critical 4-20mA signals in remote locations that need to be brought into our DCS for trending and alarming. These signals are critical to our day-to-day production schedules. Can the NET ConcentratorSystem® be used with the fiber backbones that are already in place?

Utilize Fiber Links for Critical Remote Signals Problem Solvers Moore Industries
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Solution: By implementing fiber switches, a redundant fiber ring can be established between the remote locations and the control room. The NCS can then accept the 4-20mA signals from the field and transport them via fiber to the control room where they are converted by the NCS back to the original 4-20mA signals.

Model Number Examples
EMM / COM / SM / 20-30DC [DIN]
AIM / IO / AI4 / IP [DIN]
AOM / IO / AO4 / IP [DIN]

Problem: We have several dispersed locations throughout the county where we need to access fluid levels and pump parameters at lift stations. Do you have a solution that can be remotely installed to monitor analog and discrete signals and then transmit them via a wireless data link?

Transfer Critical Signals Over a Wireless Data Link Problem Solvers Moore Industries
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Solution: Use the NCS NET Concentrator System to collect the analog and discrete signals from the dispersed lift stations. Then use our WNM Wireless Network Module to send the data over a wireless network back to the control system. At the opposite end of the data link, an NCS station collects the data from the Wireless Network Module, and then re-create the original analog and discrete signals for direct input into your control system.

Model Number Examples
EMM / COM / SM / 20-30DC [DIN]
AIM / IO / AI4 / IP [DIN]
DIM / IO / CC8 / IP [DIN]
AOM / IO / AO4 / IP [DIN]
ROM / IO / RNO8 / IP [DIN]

Problem: We’ve added a small boiler on the far side of the plant and we would like to historically trend the steam temperature profiles with our DCS historian. There are plenty of spare 4-20mA inputs on our DCS. Unfortunately, we have run out of twisted wire pairs to get the signals from the field to the DCS. We do, however, have a newly-installed Ethernet backbone. Do you have a way to convert the temperature sensor signals to Ethernet, and then convert the signals from Ethernet to 4-20mA signals for our DCS input cards?

Temperature Sensor to Ethernet to Analog Signal Conversion Problem Solvers Moore Industries
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Solution: Our NCS NET Concentrator System® allows sensor inputs to be converted to a digital signal and then transmitted over Ethernet. Using our channel-mapping capabilities enabled by the ISaGRAF Control Engine Software, any input channel can be assigned to any output channel in the network. In this application, the NCS essentially becomes an Ethernet temperature transmitter.

Model Number Examples
EMM / COM / SM / 20-30DC
TIM / IO / TI4 / IP [DIN]
AOM / IO / AO4 / IP [DIN]

Problem: We have added a small mixing tank on the far side of the plant and we would like to montior the temperature transmitters with our DCS. There are plenty of spare 4-20mA inputs on our DCS. However, we have run out of spare twisted pair to get the analog signals back to them. We do have an Ethernet backbone. Do you have a product that can accept 4-20mA signals at the field location and transmit those signals via Ethernet to another module that can convert the signals back to 4-20mA?

Peer to Peer Distributed IO Network Over Ethernet Problem Solvers Moore Industries
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Solution: Our NCS NET Concentrator System® accepts the 4-20mA signals and converts them into digital form that can be transmitted on the Ethernet backbone. At the opposite end of the data link, the NCS converts the digital signal back to identical representations of the original 4-20mA signals for direct input to the DCS analog input cards. Using this, you won’t have to install new twisted pair wiring.

Model Number Examples
EMM / COM / SM / 20-30VDC [DIN]
AIM / IO / TI4 / IP [DIN]
AOM / IO / TO4 / IP [DIN]

Problem: We have seven signals in one remote location and eight in another that we want to bring into our existing PLC control system. Do you have a remote I/O product that can be placed on a twisted pair and digitally bring signals back to the MODBUS RTU port on our PLC?

Peer to Host Data Collection Over Twisted Pair Problem Solvers Moore Industries
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Solution: The NCS NET Concentrator System® allows any mix of analog, temperature (RTD and thermocouple) and discrete inputs and outputs in a network. Data can be sent via MODBUS RTU HOST. You can daisy chain up to 255 NCS slaves onto this network. The NCS also has an OPC server available for those host systems that don’t support MODBUS RTU.

Model Number Examples
EMM / COM / SM / 20-30DC [DIN]
AIM / IO / AI4 / IP [DIN]
DIM / IO / CC8 / IP [DIN]

Problem: We have dispersed locations in the field with each having eight to 10 signals that we want to bring into our existing HMI SCADA system. Do you have a remote I/O product that can be placed throughout the plant and communication with our HMI via our Ethernet backbone?

Peer to Host Data Collection Over Ethernet Problem Solvers Moore Industries
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Solution: The NCS NET Concentrator System® allows any mix of analog, temperature (RTD and thermocouple) and discrete inputs and outputs in a network. Data can be sent via Ethernet to your HMI. The NCS supports OPC and MODBUS/TCP protocols, which are both supported by all HMI strategies.

Model Number Examples
EMM / COM / SM / 20-30DC [DIN]
AIM / IO / AI4 / IP [DIN]
DIM / IO / CC8 / IP [DIN]

Problem: During a shakedown for a new control system, we discovered that 42 signals from the hydrocracker had developed ground loops. Do I have to buy 42 isolators to fix it?

Multiple Ground Loops Plague Oil Refinery Problem Solvers Moore Industries
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Solution: Just 3 CCS Cable Concentrator Systems can do the same job for up to 48 signals. The CCS isolates each field signal, concentrates it onto a twisted wire pair with up to 127 other signals, and transmits it back to the DCS using MODBUS RTU protocol. The CCS network also frees up wires in your multi-core cables.

Model Number Example
IMM / U / RS485 / 18-30DC / –MBR [DIN]

Problem: We have remote storage locations scattered throughout the country that store inventory. Our service engineers would like to check the critical temperature and other measurements at the remote locations as they travel. Unfortunately, we only have analog telephone lines at each location. Do you have a solution that would enable them to use their laptops to check the temperature from anywhere?

Monitoring Remote IO Sites Over Telephone Lines Problem Solvers Moore Industries
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Solution: The NCS NET ConcentratorSystem® collects any combination of temperature, analog and discrete signals at the remote sites. It feeds them to an Ethernet telephone modem, which transfers the signals any distance back to a PC equipped with an analog telephone modem. Since the NCS has an embedded web server, the status of all of these signals can be viewed with any PC over an intranet or the internet using Internet Explorer™. The NCS even provides data logging for historical collection of the dispersed process data.

Model Number Examples
EMM / COM / SM / 20-30DC [DIN]
AIM / IO / AI4 / IP [DIN]
TIM / IO / TI4 / IP [DIN]
DIM / IO / CC8 / IP [DIN]

Problem: The EPA requires us to log flow and temperature data from our smoke stacks. Currently we are using a historian package called Pi from a company called OSI. Since these signals are not used for control, we really don’t want to take them to our expensive I/O cards in our DCS. Do you offer cost-competitive I/O that could connect to our historian over our plant Ethernet backbone?

Interface with OSI Pi Historian Problem Solvers Moore Industries
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Solution: The NCS NET Concentrator System®, as standard, provides the provision to communicate over Ethernet. The NCS gathers data from our universal I/O modules and sends that data over 10/100Base-T Ethernet. It supports OPC and MODBUS/TCP. We offer an OPC server for the NCS that can be loaded on any PC or Windowsbased workstation. The OSI Pi Historian has an OPC client interface that allows collection of these monitoring points. Pi Historian also supports MODBUS/TCP.

Model Number Examples:
EMM / COM / SM / 20-30DC [DIN]
AIM / IO / AI4 / IP [DIN]

Problem: We have various process signals in remote locations that we want to bring into our existing control system which operates on a 4-wire MODBUS network. Do you have remote I/O that can communicate via 4-wire MODBUS?

Interface with 4 Wire MODBUS RTU Control Systems Problem Solvers Moore Industries
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Solution: The NCS NET ConcentratorSystem® allows any mix of analog, temperature (RTD and thermocouple) and discrete inputs and outputs in a network. The NCS converts the signals to a standard MODBUS RTU communications protocol (RS-485), which can be sent long distances back to the 4-wire control system. An RS-485 Isolator/Repeater, such as the one offered by B&B Electronics, is used to convert the NCS’s 2-wire RS-485 to the 4-wire RS-485 required by the control system. MODBUS RTU works fine over both 2- and 4-wire RS-485 networks.

Model Number Examples
EMM / COM / SM / 20-30DC [DIN]
AIM / IO / AO4 / IP [DIN]
DIM / IO / CC8 / IP [DIN]

Problem: We have just updated our plant with a new DeltaV control system. We have discovered that there are a few locations where we would like to have access to additional temperature and pressure points for alarming in the DeltaV Alarm Manager. However, we cannot justify the high cost of installing DeltaV I/O for just a few points. Do you offer any cost-effective I/O solutions that could connect to our DeltaV over our existing plant Ethernet backbone?

Interface Transmitter Signals to DeltaV Over Ethernet Problem Solvers Moore Industries
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Solution: Use the NCS NET Concentrator System® to gather data from the additional monitoring sites and send the data back to the DCS over the existing 10/100Base-T Ethernet backbone. The NCS is available with an OPC server that can be loaded onto any PC or the DeltaV workstation. Since DeltaV supports OPC, you can use our more affordable NCS I/O as a front end to the alarm manager software.

Model Number Examples
EMM / COM / SM / 20-30DC [DIN]
AIM / IO / AI4 / IP [DIN]

Problem: There are points within our plant that we manually log once per day. Because they are scattered throughout the plant, it is very time-consuming for one person to cover all of these locations. Since we aren’t controlling these points, is there a way that we could inexpensively monitor them from one central location?

Data Monitoring Using Internet Explorer Problem Solvers Moore Industries
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Solution: The NCS NET Concentrator System® with an Ethernet Interface Module (EIM) features an embedded web browser. From any PC that has Internet Explorer installed, you can instantly view all process data points that are connected to the NCS. The NCS also has a built-in data logger that can be used for historical archiving should the remote PC lose communication with the measurement points.

Model Number Examples
EMM / COM / SM / 20-30DC [DIN]
AIM / IO / AI4 / IP [DIN]
DIM / IO / CC8 / IP [DIN]

Problem: We need to send large numbers of process signals from our remote processing plant back to our main control room. We are looking for an economical remote I/O solution that can communicate over a radio link.

Concentrate Signals to Reduce Wiring Costs Problem Solvers Moore Industries
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Solution: Our NCS NET Concentrator System® will accommodate both high level and low level signals for input and output and is modularly expandable to thousands of channels. It can communicate over radios, telephone modems, fiber optic or direct wire using Ethernet and MODBUS RTU protocols directly to your DCS or PCbased SCADA system.

Model Number Examples
EMM / COM / DM / 20-30DC [DIN]
TIM / IO / TI4 / IP [DIN]
AOM / IO / AO4 / IP [DIN]
DIM / IO / CC8 / IP [DIN]

Problem: We have remote compressor stations throughout the plant that are currently monitored by antiquated analog gauges and meters. We would like to upgrade to a rugged field I/O that can monitor 4-20mA signals from temperature and pressure transmitters and send the data back via MODBUS RTU over an in-place twisted pair. Ideally, we would like a redundant network so we can take data to both a remote monitoring cabinet and to our new DCS historian. Do you have a I/O system that can handle this?

Compressor Station Monitoring Using Redundant MODBUS Problem Solvers Moore Industries
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Solution: The NCS NET ConcentratorSystem® allows you to build a MODBUS RTU remote I/O network that can simultaneously communicate with two independent MODBUS masters. Any combination of input and output I/O modules can then be added, or expanded, to monitor the various remote points. To accommodate mounting at the compressor sites, the NCS operates at ambient temperature ranges of -40°C to +85°C (-40°F to +185°F).

Model Number Examples
EMM / COM / SM / 20-30DC [DIN]
AIM / IO / AI4 / IP [DIN]

Problem: We need to use the output from one temperature transmitter from the process to control two valves...one for the heating system and one for the cooling system.

Split Range Valve Control Problem Solvers Moore Industries
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Solution: Use two IPH2 transmitters in conjunction with our SIY PCProgrammable Signal Isolator Converters to control the valves. One SIY configured for 12-4mA (reversed) and the other for 12- 20mA. At 12mA the setpoint is satisfied and both valves are closed.

Model Number Example
SIY / PRG / 4-20MA / 10-42DC [DIN]
IPH2 / 4-20MA / 3-27PSIG / 35PSI /-FR1 [WDNA]

Problem: We are upgrading our brewery to a centralized DCS and eliminating pneumatic controllers. Our flow transmitters are working great and they’re staying. How can we cut the cost of running pneumatic tubing to the DCS?

Save Money By Replacing Pneumatic Tubing Problem Solvers Moore Industries
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Solution: Install a PIH Pressure-toCurrent transmitter next to your flow transmitter. This enables you to replace most of the tubing with a less costly twisted-wire pair for sending information to the DCS. Installing an IPH2 Current-toPressure Transmitter next to your DCS will cut your tubing costs from the DCS to your pneumatic control valve.

Model Number Example
PIH / 3-15PSIG / 4-20MA / 12-42DC [WDNS]
IPH2 / 4-20MA / 3-15PSIG / 20PSI / -FR1 [WDNS]

Problem: Vibration from the valves on my offshore oil rig is causing very jumpy valve operation on my existing I/Ps. I’m looking for an I/P converter that can accurately regulate the valve and withstand high vibration.

IP Conversion in High Vibration Environments Problem Solvers Moore Industries
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Solution: For precise pipeline valve regulation, look to our IPX Explosion-Proof Field-Mount I/P Transmitter. It converts a 4-20mA signal to a proportional 3-15psig for stable pneumatic valve control. It features NEMA 4X and IP65 ratings and operates flawlessly even when mounted next to a valve or other highvibration equipment.

Model Number Example
IPX / 4-20MA / 3-15PSIG / 20PSI [EXIP]

Problem: To complete the upgrade of our processing line, we must transmit twice as many pneumatic signals. We must add 32 I/Ps and 16 P/Is to the control panel but have a very limited amount of space.

Crowded Pneumatic Cabinet Needs More Signals Problem Solvers Moore Industrie
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Solution: Our slim IPT2 and PIT pneumatic transducers provide superior performance in limited space. Up to eight IPT2 s or 12 PITs fit on one foot of DIN rail. All 48 of your units will fit easily into a 36”x36”x8” enclosure.

Model Number Example
IPT2 / 4-20MA / 3-15PSIG / 20PSI / -FA1 [DIN]
PIT / 3-15PSIG / 4-20MA / 12-42DC / -RTB [DIN]

Problem: We would like to monitor the three phases of power sourcing the main process motor and send an alarm if there is a power loss on any leg of the phase.

Warn of Power Loss to Process Motor Problem Solvers Moore Industries
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Solution: Connect the 0-5AAC signal from the CT on each phase of the motor to an ECA. The ECA will provide a relay output when the current in its phase drops below a predetermined value. This will alert the technicians to an imbalance or failure of one of the phases.

Model Number Example
ECA / 0-5AAC / DH1L1 / 24DC [DIN]

Problem: We’re replacing the pressure switch with a pressure transmitter on our holding tank. Can we take the 4-20mA signal and use it for our emergency shutdown system AND for trending at the DCS?

Use One Process Signal for Two Different Tasks Problem Solvers Moore Industries
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Solution: Absolutely, the SPA2 Programmable Alarm provides both emergency shutdown capability and an isolated 4-20mA retransmission of the pressure signal for trending in the DCS. The SPA2 also provides a local indication of the pressure and relay status indicators.

Model Number Example
SPA2 / HLPRG / 1PRG / U /-AO [DIN]

Problem: I want to use a single device to provide local indication of temperature, alarm and shutdown relays. I also need to send an isolated 4-20mA signal to my DCS for the same temperature. Can I use the same device for all of these functions?

Shutdown System Needed at Refinery Problem Solvers Moore Industries
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Solution: Yes! The SPA2 Programmable Alarm Trip that takes temperature sensor inputs (-TPRG) provides all of these functions in a single instrument. In fact, you can even set one of the relays to alert you to a failed sensor without initiating an alarm or shutdown. The SPA2 can be supplied in our NEMA 4X R-BOX enclosure for field mounting.

Model Number Example
SPA2 / TPRG / 4PRG / U / -AO [DIN]

Problem: I need a low pressure alarm on my instrument air system, but I can’t afford to have a system shutdown if the pressure transmitter fails and the header pressure is still acceptable. I also want to use the signal for monitoring in the Control Room.

Open Circuit Detection for 4 20mA Input Problem Solvers Moore Industries
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Solution: A SPA2 Programmable Alarm with a dual relay and analog output will do the job. Set Relay 1 with a time delay to close when the header pressure falls below an acceptable level and Relay 2 to open if the pressure transmitter fails so a shutdown will not occur.

Model Number Example
SPA2 / HLPRG / 2PRG / U / -AO [DIN]

Problem: We upgraded to a DCS with alarms programmed directly into the software, but our insurance company requires a hard alarm backup. Is that standard operating procedure?

Hard Alarm Required for Insurance Policy Problem Solvers Moore Industries
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Solution: Yes! Many plants are adopting the new standards that require redundant alarm devices... especially for critical loops or processes. We supply systems with varying levels of redundancy dependant on how critical the application. Safety Instrumented Systems may be designed modularly to meet most any requirement.

Model Number Example
SPA2 / HLPRG / 4PRG / U / -AO [DIN]

Problem: We use 3 K-type T/Cs to monitor the burn-off flame of our emissions flare stack. However, when the wind blows, the flame leaning away from the stack gives a false out.

Flare Stack Burn Out Problem Solvers Moore Industries
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Solution: Change your strategy to rely on low readings from two T/Cs to indicate no flame in a 2-out-of-3 voting scheme. This ladder rung approach creates a “flame out circuit” ONLY in the event that two of the three alarms are tripped. The SPA2 Programmable Alarm Trip’s time delay capability also helps prevent false trips.

Model Number Example
SPA2 / TPRG / 2PRG / U / -DPDT [DIN]

Our loop requires two alarms: one to warn the control room and a second for emergency shutdown. Is there an inexpensive way to accomplish this?

Dual Alarm Warns Prior to Full Shutdown Problem Solvers Moore Industries
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Absolutely. Our SPA2 Programmable Alarm Trip with two relays accepts the 4-20mA input from your transmitter then provides two relay outputs to your DCS... one for warning and the other for shutdown. Industry-best RFI protection and FM Class I, Div 2 approvals make the SPA2 a great field fit for field locations too.

Model Number Example
SPA2 / HLPRG / 2PRG / U [DIN]

Problem: We have a pump doing heavy labor on our tank farm. In the past the bearings have overheated and caused the complete failure. How can we avoid future problems?

Avoid Motor Damage from Overheated Bearings Problem Solvers Moore Industries
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Solution: Use an ALX Alarm linked to a TDY Temperature Transmitter. When the bearings get too hot, the ALX will alarm and switch off power to the motor. After a cooling-off period, the ALX resets automatically, requiring little manual intervention once installed.

Model Number Example
ALX / 4-20MA / H1 / 6.3VLP [BH2NS]
TDY / PRG / 4-20MA /10-42DC [BH2NG]

Problem: We just lost a DCS input card due to a transient spike hitting our loop wiring and creating a damaging voltage surge to the input of the DCS.

Safeguard Expensive IO Cards from Overloading Problem Solvers Moore Industries
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Solution: Stay clear of transients, surges and spikes with the HIX HART® Isolator. It provides isolation while “passing through” both the analog 4-20mA and HART digital signal undisturbed.

Model Number Example
HIX / 4-20MA / 4-20MA / 12-42DC [DIN]

Problem: We need to transmit data from a Smart HART transmitter to both a primary DCS and an emergency shutdown device. Can we do this without placing a further burden on our process loop?

Monitoring and Powering a 2 Wire Transmitter Problem Solvers Moore Industries
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Solution: Use the 2-wire HIX HART Isolator to safely share a HART signal between two receiving devices. It sends fully-isolated instrument loops to both the primary DCS and a secondary HART master (such as an emergency shutdown device). This allows for redundancy without taxing the process loop.

Model Number Example
HIX / 4-20mA / 4-20mA / 12-42DC [DIN]

Problem: We’re experiencing signal drift between the 4-wire field transmitter and the grounded receiver on our newly commissioned loop. What’s causing this problem?

Stop Ground Loops Problem Solvers Moore Industries
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Solution: The difference in potentials between two grounded, non-isolated devices may result in a ground loop. Installing an SIY or ECT to break the galvanic path prevents the effects of ground loops, motor noise and electrical interference.

Model Number Example
SIY / PRG / 4-20MA / 10-42DC [DIN]
ECT / 4-20MA / 4-20MA / 12-42DC [DIN]

Problem: Even with a current transformer, a dangerous 0-5 amp AC signal enters our instrument cabinet. We would like to keep power levels in a safer range for our instrument technicians.

Step Down Unsafe High Level Signals Problem Solvers Moore Industries
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Solution: Install an ECT with the -EM option. It provides a “mini” external input transformer to step down the 0-5 amp signal to a lowlevel 0-5mA signal into the ECT. The ECT then transmits a 4-20mA signal to the receiving instrument. This permits safe servicing without disconnecting the main CT.

Model Number Example
ECT / 0-5AAC / 4-20MA / 12-42DC / -EM [DIN]

Problem: We need to use the output from one temperature transmitter from the process to control two valves...one for the heating system and one for the cooling system.

Split Range Valve Control Problem Solvers Moore Industries
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Solution: Use two IPH2 transmitters in conjunction with our SIY PCProgrammable Signal Isolator Converters to control the valves. One SIY configured for 12-4mA (reversed) and the other for 12- 20mA. At 12mA the setpoint is satisfied and both valves are closed.

Model Number Example
SIY / PRG / 4-20MA / 10-42DC [DIN]
IPH2 / 4-20MA / 3-27PSIG / 35PSI /-FR1 [WDNA]

Problem: For a custody transfer application, we need to monitor the input from a field flow transmitter at two locations simultaneously. What’s our easiest option?

Share a Process Signal at Two Locations Problem Solvers Moore Industries
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Solution: The dual-output ECT signal splitter takes the input from one transmitter and sends two identical isolated outputs to two receiving devices for monitoring, recording or control.

Model Number Example
ECT / 1-5V / 2X4-20MA / 24DC [DIN]

Problem: I use PLCs to control Variable Frequency Drives (VFD) in my process, but routinely have problems with feedback noise affecting the output card.

RFI Plagues Variable Frequency Driver Problem Solvers Moore Industries
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Solution: Place an input looppowered isolator like our SCX into the loop. No dedicated power supply is necessary and when ordered with the -RF option, the SCX ends noise problems with 50 V/m of protection for your PLC input cards.

Problem: We have several loops where we need to use 4-wire transmitters connected to a DCS. However, the DCS is powering its input loops, causing a conflict with the powered transmitters.

Put an End to Bucking Power Supplies Problem Solvers Moore Industries
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Solution: Installing an ECT will quickly put an end to your “bucking” power supplies. The ECT operates with powered inputs from both sides, restoring normal loop operations.

Model Number Example
ECT / 4-20MA / 4-20MA / 12-42DC [DIN]

Problem: The signal from our field transmitter is sent to both our DCS and a PLC in a remote area. The trouble is that disconnecting the leads at the PLC results in a loss of signal to both.

Protect Your Loop with Area Isolation Problem Solvers Moore Industries
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Solution: Installing a buffer, like the SIY PC-Programmable Signal Isolator, prevents a failure at the PLC from propagating to the DCS. It also breaks the common galvanic path, effectively eliminating development of a ground loop.

Model Number Example
SIY / PRG / 4-20MA / 10-42DC [DIN]

Problem: We have a project to expand our plant that includes monitoring of many non-isolated process signals. We’re looking for high-density DIN mounting, low cost and high performance.

 

One Isolator Can Take the Place of Two Problem Solvers Moore Industries
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Solution: The dual-channel ECT offers two independent, high performance isolation channels in one enclosure. The pricing, high density mounting capability and simplified wiring add up to big savings for your application.

Model Number Example
ECT / 2X4-20MA / 2X4-20MA / 117AC / -TX [DIN]

Problem: Our compressor station uses a 24Vdc battery as the primary source for powering process instruments. We’d like to monitor the battery voltage levels back at the control room...any suggestions?

Monitoring Battery Voltage Problem Solvers Moore Industries
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Solution: One way is to use our SIX Signal Isolator. It accepts the battery voltage as an input and provides a proportional 4-20mA output signal to the DCS for monitoring.

Model Number Example
SIX / 0-30V / 4-20MA / 12-42DC / - ATL [DIN]

Problem: We upgraded to new HART smart field transmitters but are still using our original field mounted isolators. Now we can’t access the HART transmitters from the control room. Is there a solution?

 

Isolator Passes HART Digital Signal Problem Solvers Moore Industries
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Solution: Our HIX HART® Isolator offers full isolation and complete HART communication capabilities. • HART signal “passes” through • Get status at any termination point • One HART signal can be used by both the primary and secondary masters.

Model Number Example
HIX / 4-20MA / 4-20MA / 12-42DC [DIN]

Problem: We have a ground loop problem between an old 4-wire field transmitter and our PLC. We want to install an isolator to break the galvanic path, but the PLC can’t power the loop and we don’t want to buy another power supply. Can you help?

Isolator Gets Power From the Input Side of Loop Problem Solvers Moore Industries
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Solution: Definitely! The 2-wire, inputloop powered ECT gets its operating power from its input side. You can power it from the 4-wire transmitter without adding a power supply.

Model Number Example
SCX / 4-20MA / 4-20MA / 5.5VLP [DIN]

Problem: After installing several HART smart field devices into our process, we found the HART FSK signal was being interpreted by the DCS as noise and causing control upsets. We want to utilize the benefits of HART but can’t tolerate the upsets!

HART Signal Interference Problem Solvers Moore Industries
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Solution: Choose our ECT, FCT, or SIY to serve as “HART Stoppers”. They pass the 4-20mA but block the FSK signal to the DCS. When mounted in the control room, access to the HART signal can still be accomplished on the input side to utilize the HART benefits you had expected.

Model Number Example
ECT / 4-20MA / 4-20MA / 12-42DC [DIN] (shown)
FCT / 4-20MA / 4-20MA / U [DIN]

Problem: We are using a common power supply for several loop powered transmitters that are wired back to different receiving devices and input cards. I am concerned about ground loop problems.

Cut Costs With Power Supply Sharing Problem Solvers Moore Industries
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Solution: You should be! Use the ECT Signal Isolator/Converter. A single 24Vdc power supply can then power multiple loops. The ECTs break the galvanic path between devices and prevent the ground loops that can come from multiple devices sharing a common loop.

Model Number Example
ECT / 4-20MA / 4-20MA / 5.5VLP [DIN]

Problem: I have an odd-shaped storage tank. The output from my level transmitter doesn’t correspond to volume because of the nonlinear relationship. I have the strapping data for my tank, but my PLC is overloaded and can’t perform the linearization function. Any solutions?

Custom Linearization Handles Odd Shaped Tank Problem Solvers Moore Industries
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Solution: The SIY PC-Programmable isolator has an 85-point linearization function that will easily handle this problem. Simply enter the strapping data into the table, and it will be linearized and scaled to provide a 4-20mA output proportional to volume.

Model Number Example
SIY / PRG / 4-20MA / 10-42DC [DIN]

Problem: We want to transmit the firing rate signal from our Boiler Control System (BCS) to our DCS for analysis. However, the BCS has a 0-10Vdc firing rate signal and the DCS will accept only 4-20mA.

Convert Signal for DCS Analysis Problem Solvers Moore Industries
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Solution: Introduce the ECT Signal Converter to the loop. It accepts many non-standard inputs and delivers a 1000Vrms isolated 4-20mA output to your DCS.

Model Number Example
ECT / 0-10V / 4-20MA / 117AC [DIN]

Problem: We need a cost effective way to monitor and control our gas compressor engine using a PLC in an unmanned compressor station.

Compressor to PLC Interface Problem Solvers Moore Industries
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Solution: Our FDY Frequency-toDC Transmitter accepts a frequency input from a mag pickup monitoring the gearing of a gas compressor engine. It converts this into a 4-20mA signal to send to the PLC so it can provide proportional engine control at a fraction of the cost of using frequency input cards for the PLC.

Model Number Example 
FDY / PRG / 4-20MA / 12-42DC [BH2NG]

Problem: How can I provide an additional HART output loop to share process signals between existing systems?

Additional HART Loops to Share Process Signals Problem Solvers Moore Industries
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Solution: Use the HIT and HIX HART Isolators. They are single input/single output isolators that pass the digital component of the HART signal from the input to the output. The input can be connected inn series with the original HART loop before the isolated output is connected to an alternate receiver.

Model Number Example
HIX / 4-20mA / 4-20mA / 12-42DC [DIN]

Problem: We need to add a 250 ohm load (PID controller) to our temperature loop. However, this would exceed the 600 ohm loop maximum. Is there an inexpensive way to get around this problem?

 

Boost Power to an Overloaded Loop Problem Solvers Moore Industries
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Solution: The low input impedance (25 ohms) and high drive capability (600 ohms) of our 2-wire ECT provides the increased capacity you need for your loop. You’ll have room for the new PID controller as well as future expandability.

Model Number Example
ECT / 4-20MA / 4-20MA / 12-42DC [DIN]

Problem: How can I implement a Safety Instrumented Function (SIF) into my Safety Instrumented System (SIS) and still monitor a critical signal or loop within an auxiliary system?

Using the SSX to Isolate Your Safety Instrumented System Problem Solvers Moore Industries 
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Solution: The exida-approved, SIL 3-capable SSX Safety Signal Isolator provides area isolation between your SIS and auxiliary monitoring system. The SSX is output loop powered, so even if power is removed on the SSX’s output side, the SIS loop continues to function with no problems. Moreover, the SSX passes HART signals so critical diagnostic and calibration data can be seen on the output side of the SSX.

Model Number Example
SSX / 4-20mA / 4-20mA / 12-42DC [DIN]

Problem: How can I share a process signal that is part of my SIS (Safety Instrumented System) with my monitoring system that also uses a HART-based Asset Management package?

Passing HART Signals While Maintaining Safety Isolation Problem Solvers Moore Industries
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Solution: Use the 2-wire SSX Isolator. Its built-in HART pass-through technology allows for valuable HART data to be read on either side of the unit. Almost all other isolators block and “strip off” the HART signal. This allows you to isolate your Safety Instrumented System (SIS) from your process control or monitoring system and allows that valuable HART data to be passed on to your asset management package.

Model Number Example
SSX / 4-20mA / 4-20mA / 12-42DC [DIN]

Problem: Exothermic reactions in batch reactors can create thermal runaways where rising temperatures can lead to dangerous conditions.

Monitoring for Thermal Runaways Due to Exothermic Reactions Problem Solvers Moore Industries 
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Solution: The SIL 2/3-capable STZ Functional Safety Dual Input Smart HART Temperature Transmitter allows either of the sensors or inputs to be designated as the primary measurement, with the secondary input acting as the backup sensor in case of primary sensor failure. This helps to mitigate potential thermal runaways before they become hazardous.

Model Number Example
STZ / PRG / 4-20MA / 12-42DC / [BH2NG]

 

Problem: Critical compressors often need an independent safety protection system to prevent over-speed conditions from developing which can damage equipment and endanger personnel and facilities.

Monitoring Critical Compressors to Prevent Over Speed Problem Solvers Moore Industries
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Solution: The SFY can be used as part of the Safety Instrumented Function (SIF) to monitor compressor speed and provide data to a safety logic solver. To accomplish this, a magnetic pickup is attached to the compressor shaft. The pickup provides a frequency output. The SFY takes the pickup signal, converts it to a 4-20mA output proportional to the shaft speed, and transmits it to the SIS Logic Solver. Should there be an unwanted change in speed, it can be detected at the Logic Solver. This helps mitigate compressor damage or personnel injuries.

Model Number Example
SFY / PRG / 4-20MA / 12-42DC / [BH2NGP]

 

Problem: We’re upgrading our pulp mill. What’s the best way for me to interface existing thermocouple (T/C) signals with our DCS?

Universal Temperature Transmitters Cut Costs Problem Solvers Moore Industries
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Solution: Choose a temperature transmitter from our extensive product line. You’ll get improved measurement accuracy, lower wiring costs, isolation, linearization and protection from RFI/EMI interference.

Model Number Example
TRY / PRG / 4-20MA / 10-42DC [DIN]

Problem: It’s increasingly expensive to stock the various DCS input cards required by all the temperature applications around my facility. How can I economize?

Universal Temperature Transmitters Cut Costs Problem Solvers Moore Industries

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Solution: Cut down on stock and maintenance costs with a universal TRY PC-Programmable Transmitter. It accepts any standard temperature sensor input and sends an isolated 4-20mA signal to the DCS. This means you need only one type of input card (4-20mA) for all your applications. Many of our other transmitters offer similar capabilities.

Problem: We are wasting hundreds of man-hours each year on maintenance issues with our temperature sensors. There must be a better way.

Total Sensor Diagnostics Cuts Time and Cost Problem Solvers Moore Industries

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Solution: The SPT SiteProgrammable Transmitter with patented Total Sensor Diagnostics takes the guesswork out of identifying and locating sensor problems. Error messages in plain English guide you directly to the source of failure. Our other transmitters offer similar capabilities.

Problem: Precise temperature calibration is time-consuming. Is there a better alternative?

Temperature Calibration Made Easier Problem Solvers Moore Industries

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Solution: Hook up your sensor or calibrator to the TDY PCProgrammable Temperature Transmitter with Display. The point and click software enable immediate capture of two points within your desired range thus input calibrating the transmitter. This method produces an extremely accurate measurement in just seconds.

Model Number Example
TDY / PRG / 4-20MA / 10-30DC [BH2NG]

Problem: My utility plant has lost thousands of dollars due to false shutdowns from failed temperature sensors. How do I know the difference between a failed sensor and a true alarm situation?

Prevent False Shutdowns Problem Solvers Moore Industries

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Solution: Use the SPA2 Programmable Alarm. Any of its two or four relay alarms can be programmed to trip on an “open sensor” without tripping the high-temperature warning or shutdown alarms. Sensor failures will not trip the process.

Model Number Example
SPA2 / TPRG / 2PRG / U [DIN]

Problem: We pressure and temperature compensate the volumetric flow readings in our pipeline applications. The temperature accuracy is critical, especially for gasses such as ethylene that see larger changes in mass as temperature changes.

Mass Flow Temperature Compensation Problem Solvers Moore Industries

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Solution: Install the absolute best and most accurate temperature measurement solution available. Our TDZ2 HART Temperature Transmitter has 20-bit input resolution and offers better than ±0.05°F system accuracy with a matched RTD. You’ll save thousands of dollars annually due to improved compensation accuracy.

Model Number Example
TDZ2 / PRG / 4-20MA / 12-42DC [BH2NG]

Problem: Inaccuracies and excessive drift with our existing temperature transmitters are causing fluctuations in our clean room temperature. The off-spec product and frequent recalibrations are costing big dollars. There must be a better alternative.
High Accuracy Clean Room Monitoring Problem Solvers Moore Industries

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Solution: You’re right. By using our calibrated temperature monitoring solutions (utilizing our precision transmitters with 4-wire RTDs in the air distribution system and in the room itself), your control system can maintain ambient temperature levels and increase production yields. Maintenance costs are also dramatically reduced due to long term stability and decreased calibration frequencies.

Model Number Example
TRY/PRG/4-20mA/10-30DC/-ISA [LH1NS]

Problem: We need to replace obsolete computing modules used to calculate the average temperature in our oven. Is there a better way to accomplish this averaging?

Get the Average of Three RTD Signals

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Solution: One Moore Industries SPT can take the three RTD signals, calculate their average, then display and retransmit the value to your DCS or recorder.

Problem: My temperature transmitter produces a false spike before driving downscale on burnout. This causes an expensive safety shutdown. Any suggestions for an alternative?

 False Spike Leads to Expensive Shutdowns

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Solution: Try our TDY PCProgrammable Temperature Transmitter. When the TDY first detects an open input, the last output is frozen. Upon reconfirmation of open input, it drives downscale.

Model Number Example
TDY / PRG / 4-20MA / 10-30C [D1LC]

Problem: Our DCS measures the entire range of our temperature sensors. For our RTDs, that’s a span of almost 1900°F when our range of interest is only 0-250°F. The DCS input card accuracy is calculated as a percent of the 1900°F span. How can I improve my accuracy numbers?

 Enhance Accuracy Using Transmitters

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Solution: Our TRY Temperature Transmitter can be calibrated to any specific range. Since transmitter accuracy is a percentage of calibrated span, a tighter span means better accuracy. As the range narrows, the measurement accuracy improves.

Model Number Example
TRY / PRG / 4-20MA / 10-30DC [LH1NS]

Problem: How can I monitor the temperature difference between the hot product flowing in and the cooled product flowing out of a heat exchanger (∆T)?

Differential Temperature in a Heat Exchanger

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Solution: Install RTD sensors at the inlet and outlet of the exchanger and connect them to our RIY configurable temperature transmitter. The RIY can be configured to provide a 4-20mA output proportional to the temperature difference to your DCS, recorder or other device. The difference is also displayed locally.

Model Number Example
RIY / PRG / 4-20MA / 12-42DC [BH2NG]

 

Problem: In our chemical plant, corrosion at the connection terminals causes unpredictable drift in the RTD measurements. We clean and re-calibrate regularly, but labor and off-spec product costs are no longer acceptable.

Corrosion Causes Inaccurate Measurement Problem

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Solution: Replace the old 3-wire RTDs with 4-wire sensors and use any of our family of Temperature Transmitters. Each accepts an input from a 4-wire RTD and together totally compensates for the effects of terminal corrosion. A complete replacement assembly of transmitter and sensor can be factory calibrated for optimal performance.

Model Number Example
TDZ2 / PRG / 4-20mA / 12-42DC [BH2NG]

Q. What is the purpose of increasing input resistance to 250 ohms with the IZ250 option on the Moore Industries SSX signal isolator/repeater

SSX 2Wire Isolator Moore Industries pp A. If you anticipate that the total loop resistance where your HART transmitter resides will be lower than 230 Ohms, this option will ensure you have enough impedance in the loop to create a sufficient voltage drop for reading the HART signal by a HART host (handheld or input card). The HART digital specification requires the loop to have total loop impedance between 230 and 1100 Ohms in order to initiate and maintain stable communication with HART devices.

 

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

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1 Moore IndutsriesA nutritional supplement company’s process facility contains several liquid spray driers that employ a deluge safety system. Temperature is monitored at several critical points within the drying chamber. When an abnormally high temperature value was detected, the deluge safety system would be activated by a PLC. All temperature measurements are made using 3-wire RTDs, wired directly into PLC cards. The PLC often reported significant temperature measurement errors and would sometimes return high-temperature spikes of more than 330F which would erroneously trigger the deluge safety system and destroy expensive production batches. The drier operators hypothesized that a broken wire or loose connection to an RTD would cause the RTD to read higher temperatures than were really occurring, initiating the deluge.

The customer sought to use a more reliable monitoring solution with advanced temperature measurement capabilities that would allow them to differentiate between an out of process temperature reading and a failed or faulty sensor, thus preventing unnecessary deluges and lost batches.

Temperature Monitoring of Liquid Spray Driers app
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Solution:

To provide more reliability to the overall drier temperature monitoring system, Moore Industries TDZ3 Smart HART Dual Input Temperature Transmitters were used in place of the PLC cards to read the RTD sensors. Next, the existing single element RTD sensors were replaced with dual element RTD sensors. These dual elements were wired directly to each TDZ3 transmitter and its 4-20mA signal was then wired to the PLC. If both RTD sensors failed, the TDZ3’s output was configured to fail low to 3.6mA to avoid a spurious safety trip of the deluge system. The PLC was already fitted with smart HART 4-20mA input cards, so the advanced diagnostics and additional process measurements transmitted over HART could also be read from the TDZ3 temperature transmitters.

The overall reliability of the temperature measurement system was immediately realized by using the TDZ3’s BACKUP/FAILOVER feature that enables the transmitter to accept two sensor inputs and assign them as primary and secondary. Should one of the two sensors fail, the other sensor is automatically substituted as the primary to prevent signal loss. When a failure does occur, the transmitter’s display shows which sensor failed and sends out a HART fault code to the PLC alerting operators that they have lost redundancy and service should be scheduled.

Next, to prevent false high temperature spikes from reaching the PLC, the TDZ3s were configured with an advanced measurement capability called LOW SELECT. This feature allowed the TDZ3 to monitor both sensors of the dual element RTD and assign the lower of the two readings to the transmitter’s 4-20mA output. This would always ensure that if one of the RTDs failed and started to go high, it would be prevented from reaching the transmitter’s calculated output.

But what about situations when the RTD started to fail low? To assist with determining when an RTD was failing high or low, the TDZ3 was also configured with another advanced diagnostic feature called CORROSION DETECTION. When enabled, this feature compares the two resistance readings of the two RTD inputs and alerts you if they have drifted more than your pre-established drift setpoint, say 15 ohms. Since these dual element sensors are contained in the same sheath, they should never be reading off by more than the inherent error of the sensor itself. This feature helps reduce downtime and allows convenient rescheduling of faulty sensors.

Some of the TDZ3’s advanced measurements like LOW SELECT require two good quality sensor inputs. But what if one sensor fails? Do these advanced functions still work if only one sensor is available? By default, the TDZ3’s response is to go into fail mode (output of 3.6mA). But for higher availability applications like this one, the TDZ3 has an ALLOW DROPPING feature that instructs the transmitter to continue using the one good sensor as its valid input but still throws a HART fault flag when a sensor fails. This is the configuration the drier operators chose.

Since the PLC could read the TDZ3’s HART output, additional diagnostic and process variable monitoring further enhanced the overall drier monitoring reliability. The TDZ3’s four main HART variables were configured as:Since the PLC could read the TDZ3’s HART output, additional diagnostic and process variable monitoring further enhanced the overall drier monitoring reliability. The TDZ3’s four main HART variables were configured as:

  • Primary Variable (PV) & 4-20mA – LOW SELECT
  • Secondary Variable (SV) – Sensor 1
  • Tertiary Variable (TV) – Sensor 2
  • Quaternary Variable (QV) – ABSOLUTE DIFFERENTIAL

All HART diagnostics were monitored by the PLC so any sensor failure, out of range signal or diagnostic fault would be picked up.

By utilizing the advanced measuring and diagnostic features of the TDZ3 Dual Input Smart HART Temperature Transmitters, versus the PLC to monitor drier temperatures, batch production throughput was increased and spurious safety trips of the deluge system were all but eliminated.  Additionally, monitoring the additional parameters via HART from the TDZ3 transmitters gave the PLC and their HMI historian the ability to more accurately trend and analyze individual sensors and overall drier temperature performance.

Key Attributes of the TDZ3 Dual Input Smart HART Temperature transmitter:

  • Dual Input with Sensor Backup/Failover function when using two sensors
  • Corrosion Detection capability for both sensors to predict pending failure
  • Smart HART allows delivery of additional HART variables to the PLC

 

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A refinery required a third-party certified SIL 1 solution to calculate the differential between two analyzers that measure the methane content on the inlet and outlet of a reactor, which breaks down the hydrocarbon levels in the process stream.  The methane level is always higher on the outlet side of the reactor; however, should the differential with the input exceed a predefined setpoint, these higher methane levels could reach flashpoint with a sharp trend that could lead to an explosion. 

Refinery Methan Analyzer Moore Industries

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After a Hazard and Operability Analysis (HAZOP) of the existing installation was performed, it was determined the refinery needed to mitigate the risk and install an independent SIL1 safety trip solution. Moore Industries designed a methane differential trip Safety Instrumented Function (SIF) and provided the client with an independent Safety Integrity Level (SIL) verification report.

The two independent methane analyzer measurements are sent to the SST Signal Splitters, where one output is used for the differential calculation and the other is transmitted to the Basic Process Control System (BPCS). 

The methane differential is calculated by the STZ Transmitter and sent to the STA Logic Solver, where a differential between inlet and outlet  analyzers exceeding 10% MOL will trip the safety setpoint. In addition, the STA Logic Solver retransmits the calculated methane differential to the Basic Process Control System.

Key attributes:

  • STA, SST and STZ are all SIL2/3 capable and exida certified safety components
  • SST Signal Splitters provide independence between SIF and Basic Process Control System
  • Standard off the shelf hardware, user configurable for SIS solutions

 

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An electrolytic copper refinery needed an efficient and reliable way to monitor voltage on more than 700 electrolytic cells used to produce A grade copper. The refining process in this type of plant begins with copper anodes of 99% pure copper plates produced in a copper smelter. These copper anodes are submerged in an acidic copper sulphate solution, between stainless steel “mother” plates (cathodes) in the electrolytic refinery tank house.

Using the Moore Industries NCS for Cell Voltage Monitoring

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A low voltage electric charge is fed through the tanks. Over a number of days, the copper anode dissolves into the copper sulphate solution.  The positively charged copper content migrates electrolytically from the anodes to the stainless steel mother plates where they deposit and build up into a 99.99% pure copper cathode. The impurities are separated from the copper by falling to the bottom of the tank.

Monitor copper electrolysis with NCS

Pictured here is a column of 16 electrolytic cells and their rows of electrodes in a typical electrolytic copper refinery’s tank house.
At many refineries like this the cells number in the hundreds.

The copper is then stripped from the stainless steel mother plates and the copper is shipped as melting stock to mills or foundries where it is cast into wire rod, billets, cakes, or ingots, as pure copper or is alloyed with other metals. The impurities, or tank house slimes, leftover after the electrolytic refining contain a range of other valuable minerals including gold and silver which is further processed and recovered.

Moore Industries engineered Net Concentrator System (NCS) components to perform Cell Voltage Monitoring. The NCS components included 192 TIM Temperature Input Modules measuring cell voltage drop in millivolts, housed in 12 cabinets. The complete NCS system provides critical real-time performance monitoring of the cell voltages via Ethernet, improving overall house maintenance and management. This allowed the operations staff to realize significant gains in production and the quality and amount of copper production.


Key Attributes of the NCS:

  • Modular electrically isolated I/O (500V channel-to-channel) with configurable ranging
  • Operates in harsh environments -40 to 85C ambient operating temperature
  • Quick and simple programming with Ethernet MODBUS/TCP and serial communication ports

 

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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.

 

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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.

 

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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/Zone 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 (SIS) 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

 

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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 ConversionDownload the PDF file

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 the SIY is a versatile signal converter to have on hand.  The SIY isolator is an output loop powered unit that derives its operating power from the host or receiving device.  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 the SIY is a versatile signal converter to have on hand.  The SIY isolator is an output loop powered unit that derives its operating power from the host or receiving device. 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
  • Drive Capacity: 654Ω @ 24Vdc
  • RFI Rejection: Up to 20 V/m with <0.1% span error
  • 85 Point Linearization
  • Output Damping

 

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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.

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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.

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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 or host system, 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 any standard web browser over your Intranet (or Internet) from any PC, with proper security credentials. Alternatively, our free Intelligent PC configuration software, NCS Config, can also be used for programming and viewing of real time process data via the NCS' 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.

 

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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 suitable for installation in Div 2/Zone 2 and IS hazardous locations 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. Each HMC can read two TCMs or 32 temperatures in ~2 seconds and deliver those readings 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/Zone 2, IS certified, and can tolerate ambient temperatures from -40 to + 85°C
  • HART to MODBUS conversion with the HMC

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

DCS and other BPCS used to control processes 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 and converts all gathered HART data to MODBUS/TCP. Each network can have as many as 16 devices. Assuming the transmitters support Command 9 that is eight variables we retrieve from each device. 8 variables x 16 devices 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 devices.

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

Download Datasheet

There are different technologies available to eliminate long home runs 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 DINDownload the PDF file

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

Download Datasheet

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 an existing 4-20mA loop,, 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 most anywhere.

Key Attributes:

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

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

The HES HART to Ethernet Gateway System  is the ideal multichannel HART-to-MODBUS converter, but it cannot be connected to the safety loops directly as that would negatively affect the customer’s loop reliability per IEC 61511 guidelines.

Safety Variable to MODBUS TCP
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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 to three of the four channels on the HES HART-to-MODBUS converter. The HES reads the HART dynamic variables and diagnostic data of the STZ Temperature Transmitter and maps them to MODBUS registers awaiting the communication request from the MODBUS Host.

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

Key Attributes:

  • HART-to-MODBUS conversion with the HES
  • 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/TCP

Download HES Data Sheet or SSX/SST Data Sheet

The thermal conductivity of pure hydrogen makes for an efficient cooling medium for generators. However, under normal use contaminant like oil, vapor, water or air decrease the purity of the hydrogen. As the hydrogen 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 hydrogen purity analyzer. However, the commercial issues are important enough that many will have a redundant trip source for this application.

Critical Trip H2 PurityDownload the PDF file

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 hydrogen 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 five digits and also has five 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

 

Download Datasheet

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 transmitted back to the SCADA. A good choice of instrument for this is the Moore Industries Cathodic Protection Monitoring System (CPMS).

Cathodic Protection Monitoring SystemDownload the PDF file

The typical signals off your rectifier are 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 a 4-20mA signal representing rectifier temperature. 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

Download Datasheet

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 for any RTD or TC utilized. 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

Download Datasheet

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 AccuracyDownload the PDF file

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

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Excessive wellhead pressure can cause serious consequences to downstream personnel, production and production assets and the environment. It is therefore commonplace to have IEC 61511 compliant protection systems. Companies implement various strategies but most common are 1oo2 or 2oo3 architectures for compliance to SIL 2 or SIL 3.

Wellhead HIPPSDownload the PDF file

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 push-button field programming or easy to use free PC programming software user interface is most beneficial to a cross-section of users. Plus, its high ambient temperature specifications and suitability for installation in Class I, Div 2 / Zone 2 environments make it ideal 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 Systems
  • The SIL 2/3 Capable STAs are much simpler to program than safety PLCs and cost significantly less
  • Suitable for extreme environments

Download Datasheet

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
  • Suitable for Class I Div 2/Zone 2 environments and -40 to 85C ambient operating environment

Download Datasheet

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 SplitterDownload the PDF file

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

Download Datasheet

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 is 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
  • Suitable for use in Class I, Div 2/Zone 2 areas
  • Ambient tolerance -40 to +85°C

Download Datasheet

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 the 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

View the STA in the online catalog.

Download Datasheet

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 Protection

Download 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

 

 

Download Datasheet

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

 

Download Datasheet

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 feature is implemented,, 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
  • Suitable for Class I Div 2/Zone 2 environments and -40 to 85C ambient operating environment

HPump is a trademark of Baker Hughes Incorporated

 

Download Datasheet

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

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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 Measurements
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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

 

Download Datasheet

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

Download Datasheet

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

 

Download Datasheet

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

Download Datasheet

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

Download Datasheet

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

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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

 

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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)

 

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