If redundant instrumentation is used in the drinking water storage test scenario and different devices are used, the displayed values can be directly compared with each other and conclusions can be drawn.

© Endress+Hauser

In production facilities, however, device and technology tests would be associated with a high level of risk. In the biotechnology sector, for example, plants are subject to GMP regulations that make it virtually impossible to temporarily replace one measuring device with another for testing purposes without a conformity check. In chemical production, on the other hand, ubiquitous explosion-protected areas or SIL safety devices make it difficult to test new technologies. In addition to regulatory restrictions and plant safety requirements, there are also practical reasons for not carrying out tests in productive plants: For example, the ongoing process would have to be interrupted to replace a measuring device, but this would be too costly.

Proof of concept in drinking water storage

The FieldEdge SGC500 connects the measurement technology with the Netilion IIoT ecosystem in the control cabinet.

© Endress+Hauser

For example, the IIoT ecosystem Netilion is being tested, as are augmented reality applications with lidar scanning from other providers. As various innovations are being tested in parallel, the new technologies are linked together. For example, the asset information from Netilion can be integrated into the augmented reality application. Netilion can act as a data platform and make the processed data available to other systems via Connect and API. The redundancy of the drinking water system makes it easy to replace devices. The system also offers sufficient space for extensive installations and expansions as well as for various tests. The aim behind the various pilot projects is to To use new technologies that have proven themselves in drinking water storage in production areas and roll them out to the entire plant.

Measurement technology and cloud solutions in test operation

The FieldPort SWA50 WirelessHART adapter (left) can be retrofitted to existing systems and brings measuring devices into the cloud.

© Endress+Hauser

In addition to Netilion, the tests will also focus on various new measuring devices from Endress+Hauser. These measuring instruments cover a wide range of measurement parameters: In addition to temperature sensors and pressure transmitters, an analysis panel for test measurements of the chlorine concentration in drinking water, the cloud-only level measuring device 'Micropilot FWR30' or the magnetic-inductive flow meter 'Promag W' with 'Heartbeat Technology' are also used.

Thoroughly testing devices also means stressing them: for example, the Promag W flowmeter simulates ageing or build-up in order to gain insights into the devices in productive use. For example, the electrodes could be manipulated, whereupon the device's internal heartbeat diagnostics would then issue corresponding error messages and maintenance requirements. One wish for the future is for a test cycle to run automatically in the sensor and for a report to be created automatically. This would mean that maintenance personnel would no longer have to be sent to the device for routine checks. This function, known as heartbeat verification, is part of many smart measuring devices. In order for it to be used in practice, it must be implemented in the work processes. So what already works technologically cannot always be implemented 1:1 in practice.

Netilion Value visualizes the measured values on clear dashboards, for example on a tablet PC such as the Field Xpert SMT70 from Endress+Hauser.

© Endress+Hauser

Merck sees great potential for the new IIoT technologies currently being tested in the maintenance and servicing of systems: the plan is to carry out maintenance as condition-based as possible in the future. Maintenance is currently carried out at fixed intervals, which costs money and resources. In future, maintenance intervals are to be dynamically aligned to the needs of the sensor.

This can be illustrated using the example of a billing-relevant flow measurement, which is also used in drinking water storage: this is either tested annually on a test bench or the device is monitored continuously. The savings in working time and the positive effects on system availability are obvious.

Retrofitting WirelessHART

With the WirelessHart adapter 'FieldPort SWA50', any HART-capable measuring point can be integrated into the WirelessHart network. The device is loop-powered and can be retrofitted to all HART-capable measuring points with little effort. This allows any measuring point to be brought into the cloud. The robust adapter also works with third-party manufacturers, so that at Merck all assets in the plant in the neighboring building could theoretically be integrated into Netilion with the FieldPort SWA50 via WirelessHART. The data can be used with the IIoT ecosystem to generate an overview of the plant, develop predictive maintenance strategies, optimize calibration intervals or implement mobile asset management, for example.

Level measurement values on digital dashboards

The author: Florian Kraftschik is Sales Marketing Manager Communication at Endress+Hauser Germany in Weil am Rhein.

© Endress+Hauser

Another new device from Endress+Hauser in the test is the cloud-based level measuring device 'Micropilot FWR30'. It was placed on a plastic tank containing an educt for the chlorine generator. The device works completely without cables and transmits its measured values directly to the Netilion cloud via mobile radio. The measured values and other data - such as the current position, battery status or outside temperature - are displayed in the Netilion 'Value' application on various dashboard views that can be accessed via smartphones, tablet PCs or stationary computers. The visual display of data and information offers great added value: employees can see at a glance whether the system is running within its specifications.

Gaining experience in the test environment

Merck in Darmstadt has had very positive experiences with testing new technologies such as smart sensors and Industry 4.0 solutions in the drinking water storage test environment before they go live. The devices are tested under real conditions and know-how about the technology used is gathered before it is then used for other systems and incorporated into the plant's own standards. In this environment, the hurdles in terms of regulations, Ex and SIL requirements are low. The findings from the tests can then be transferred to the instrumentation for new construction or modernization of systems.