📋 Case Study

Boiler Drum Level Measurement Upgrade at Petrochemical Refinery

Analog differential pressure transmitters failing under thermal cycling; no remote diagnostics or calibration history

🏗️ Project Overview

Modernization of critical steam generation system in Singapore refinery

🎯 Challenge

Analog differential pressure transmitters failing under thermal cycling; no remote diagnostics or calibration history

🔧 Design Approach

Deployed dual-redundant smart DP transmitters with HART + Foundation Fieldbus interface; integrated into DeltaV DCS with FDAM module

📐 Design Diagram

AI-generated project design illustration

📐 Key Calculations

Hydrostatic Level Error Budget

ρ·g·h·(ΔT/100)

Result: ±12 mm

Thermal expansion correction applied digitally

Loop Power Margin

Vsupply − (ΣVdrop + Vmin_device)

Result: +3.2 V

Ensured stable Fieldbus segment operation

📊 Results

98% uptime improvement; calibration cycle extended from 6 to 24 months; 40% reduction in manual loop checks

💡 Lessons Learned

• •Digital trim eliminates mechanical zero drift
• •FDAM integration requires standardized device descriptions (EDDL/FDI)

✅ Key Takeaways

• 1Digital trim eliminates mechanical zero drift
• 2FDAM integration requires standardized device descriptions (EDDL/FDI)