White paper: Matched-Pair Magmeter Leak Detection Accuracy Page 1

Matched-Pair Accuracy Capability of Rosemount 8700 Series Magmeters

The intent of this paper is to outline Rosemounts experience with Matched-Pair accuracy for Leak Detection and summarize the technical validity of this approach. There are two leak detection methods commonly used to monitor cooling water flows: Input/Output method: This method compares the input flow to the output flow. A leak will cause the output flow to be different than the input flow. A trigger point of as little as % difference is set up, and will alarm if exceeded. This method requires very accurate flow measurement, usually with % accuracy and very good repeatability, to detect differences of as little as gallon per minute. Frequent calibration checks are often specified to ensure the flow meters continue to operate within the required accuracy specification.

Normal flow method: The normal flow method detects a change in flow rate once the furnace operation is stabilized. Once the furnace is operating at steady state conditions, the flow rate of the output water is established, and dead bands are set around this steady state condition. If the flow rate unexpectedly drops below the low flow set point, the condition is alarmed and the process can be shut down in a controlled manner. The 4mA point is often elevated to exaggerate the flow change.

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Combination method: The two methods can be combined, with the two meters providing both the input/output and normal flow monitoring. Combining the two methods provides the best protection with minimal investment over the input/output method. These are the Application challenges: High accuracy is required to identify small leaks as early as possible. The measurement must be repeatable and reliable to prevent false alarms and nuisance furnace shut downs. The leaks must be discovered early before they create a dangerous situation. The leak detection flow meters should be self-checking to insure they are working correctly. Emersons approach highlights the solution: Use the best-in-class, most accurate flow meters to measure cooling water flow into and out of the furnace. o E-Series Magmeter High Accuracy option is 0.15% of rate +/- 1mm/sec Installed performance taking into consideration all factors that can impact measurement accuracy is important. o Repeatability is +/- 0.1% of reading o Analog output effect : It has the same accuracy as frequency output plus an additional +/- 4A o Ambient Temperature effect: +/- 0.25% change over operating temperature range o Stability is +/- 0.25 % change over six months Advanced diagnostics simplify installation, insure best performance over time, and provide continuous self testing of the components o Advanced diagnostics can look at the entire signal spectrum not just the flow signal and use this information to diagnose instrument and process issues In-situ Calibration Verification confirms performance without effecting operations. o This advanced optional diagnostic capability confirms that the meter is not only operational, but confirms that the meter accuracy has not changed. The in-situ verification technology is built into the transmitter and no additional equipment is required. The Calibration Verification can be initiated through the LOI or Asset Management Software, and can be run with no interruption to the normal process. Matched-Pair Calibration option o Rosemount has the capability to calibrate the two meters at the same time in the same line to get the best matched performance possible. o The two meters are calibrated in series and the calibration numbers are adjusted such that both meters will read the exact same flow rate. o A Calibration certificate will be issued on request

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REFERENCES: Customer 1: Arcelor Mittal Steel (formerly DOFASCO ) Location: Hamilton, Canada Application: Blast Furnace tuyere cooling water leak detection Solution: Qty 78 Rosemount E-Series high accuracy Magnetic flow meters on cooling water flows Superior accuracy at target flow rates Advanced diagnostics utilized AMS software also utilized for Diagnostics visibility and configuration Customer 2: USX Steel Location: Gary, Indiana and Clairton, Pennsylvania USA Application: Blast Furnace tuyere cooling water leak detection Solution: Rosemount E-Series magnetic flow meters on cooling water flows % accuracy at target flow rates Ability to Elevate the 4-ma point for magnified visibility to flow rate shift Enabled both types of leak detection in the Combined Method Customer 3: Severstal North America Steel Location: Dearborn, Michigan USA Application: Blast Furnace Tuyere Leak Detection Solution: Rosemount E-Series magnetic flow meters Meter Verification Advanced Diagnostics Large 12 header, along with multiple 2 individual water lines Customer 4: Hi-Smelt Location: Perth, Australia Application: Furnace cooling panels on proprietary high-temperature process Solution: Rosemount 8742C Foundation Fieldbus output Matched-pair method for early leak detection High accuracy calibration High temperatures at 2,150 F forced extreme safety focus for cooling water

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