BP improves chemical plant leak detection with wireless technology 20 May 2014

BP ha revealed that it is using 'smart' wireless technology at its Geel, Belgium, chemical plant as part of a continuous leak detection system to improve safety surveillance on storage tanks, valves and pipelines.

The chemicals giant says that wireless technology – from Emerson Process Management – provides a reliable and affordable way to automatically gather information from hydrocarbon leak sensors installed throughout the plant, and to deliver it to the control system.

It has also enabled BP to meet the latest EU regulations for storage and handling of flammable liquids – and, most importantly, at much lower cost than with traditional hard-wired technology.

"By combining Emerson's wireless technology with hydrocarbon sensors, BP has been able to expand the view that operators have and enhance its existing leak detection practices, helping to improve site safety," comments Bob Karschnia, vice president for wireless systems at Emerson Process Management.

Leak detection on large sites can be both difficult and expensive. BP operators were making twice-daily inspection rounds using portable leak detectors, but new and stricter government regulations required continuous monitoring.

Karschnia points out that a conventional online monitoring system would require new instrumentation cabling, the I/O racks, with signal converters, and all the installation costs associated with trenches and ducting.

However, the wireless system installed at Geel simply integrates liquid hydrocarbon sensors with Emerson's smart wireless technology to enable cable-free leak detection even from remote site locations.

So not only was installation by BP's maintenance team much faster than the old wired alternative, but savings have been estimated at 50% in terms of the cost and 90% of the time required.

The leak detection system itself uses Emerson's Rosemount 702 wireless discrete transmitters (based on IEC 62591 WirelessHART digital communications) combined with Pentair (formerly Tyco) fast fuel sensors and TraceTek Sensor cables.

If one of the sensors detects xylene or benzene, the associated Rosemount 702 instrument wirelessly transmits an alarm signal to one of the smart wireless gateways that relay data to the control room for incident reporting and time stamping in the host control system.

At the point of installation, the TraceTek Sensor cables have been attached to the concrete base surrounding tanks so that leaks from the tank wall would be detected. They have also also been laid underneath connecting piping and draped around the tank flanges and manholes.

Meanwhile, the Fast Fuel Sensors were installed to detect hydrocarbons in sump wells and pump skids.

"Combining Emerson's wireless technology with hydrocarbon sensors provides an ideal leak detection solution for large sites, such as production plants and tank farms," comments Karschnia.

"It's another example of how users are taking advantage of this technology to gain business benefits – including enhanced safety and regulatory compliance – in applications beyond the process itself."

Brian Tinham

Related Companies
Emerson Process Management

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