SYSTEM SOLUTIONS FOR AUTOMATION

A major refinery has decided to use the IS1+ Remote I/O system in a highly available version for monitoring and control of critical processes in Zone 2 hazardous areas. The system is supplied with redundant CPU and power modules, and it communicates with the control system via a redundant PROFIBUS DP network. Both the external 230 VAC supply and the integrated heater to prevent condensation are designed redundantly.

Temperature and humidity inside the field enclosure are constantly monitored by a sensor and communicated to the control system. All fieldbus and supply lines are fitted with surge protection.

The field enclosure consists of robust AISI 316L stainless steel and is fitted with an automatic inside light for service technicians. Of particular importance was the option for an easy retrofit for ATEX Zone 1: the CPU & power modules merely need to be replaced by Zone 1 versions - for more information on IS1+ click here:

(illustration above: redundant remote I/O system solution for Zone 2 installation / illustration below: system redundancy with intrinsically safe PROFIBUS DP and IS1 for Zone 1)

The customer uses intrinsically safe as well as pneumatic field devices in Zone 1. With the use of IS+ DOMV modules for ATEX Zone 1, separate field stations for solenoid valve islands are no longer required, and the distances for the pneumatic tubes are greatly reduced.

The DOMV modules each have eight integrated 3/2-way valves whilst only using one module slot, and they can be combined with the intrinsically I/O modules in any way. The resulting explosion-protected field stations are very compact.

Communication with the automation system takes place via an Ethernet network with either Modbus TCP, Ethernet/IP or PROFINET. Optical fibre is used to ensure interference-free transmission across distances of up to 2000 m as required in this application. With type of protection "op is", this can be easily connected and disconnected in Zone 1, simplifying extension and maintenance work – click here for more information on IS1+:

(illustration above: Remote I/O field station for Zone 1 with Ethernet and integrated solenoid valve islands / illustration below: pneumatic module for Zone 1 with eight 3/2-way valves for IS1+)

A customer needed a solution for the local control and monitoring of a gas compressor for installation in Zone 1. 

The monitoring system and the screen from Bently Nevada were integrated together with Ex i isolators and an HMI solution from R. STAHL and other components such as a PLC in an Ex p enclosure.

The customer benefited from an individually tailored solution from one provider. R. STAHL was responsible for planning and implementing this solution on the basis of customer specifications.

The Ex i isolators transmit temperature and vibration measurement signals taken from sensors to the Bently Nevada monitoring system. 

The two-channel design of the Ex i isolators meant a 50% reduction in space required - for more information on ISpac, click here

(Illustration above: outside view of Ex p cabinet / illustration below: Condition monitoring system with Ex i isolators (bottom row))

This explosion-protected CCTV system was specifically designed to withstand the extreme temperature fluctuations and ambient conditions on a drilling platform in Zone 1. The client required three different areas on the platform to be monitored with a separate station each, but connected to each other for flexible access.
All video data had to be stored on a server matrix.

Key benefits:

• Matrix with servers and switches for simultaneous monitoring in three control rooms
• Fast rotating PTZ camera monitoring the drill pipe
• High-resolution thermal imaging camera with for man overboard detection
• AFZ camera with PoE++ for room surveillance
• Server structure to store video data, enabling later control of events
• PoE++ extender for covering large transmission distances

Click here for more information on our CCTV products.

R. STAHL ORCA HMIs can be designed to meet the requirements of the process plant. Options include displays arranged vertically or horizontally, mobile HMI solutions, customised enclosures and system-specific wall mounts. Our display sizes range from 7" to 22", ensuring the right operating and monitoring device for every kind of automation solution.

Many of the operating stations can be customised with RFID card readers, barcode scanners, Bluetooth headphones and keyboards.

For modern network solutions, R. STAHL's Thin Clients can be configured with the latest Remote Firmware for simple network integration and secure communication.

For more information on our HMIs and accessories, go to

• Overview of HMI technologies
• Thin Clients in virtual networks
• RFID and barcode readers      

(illustration above: Example of an individually configured dual-monitor system for cleanrooms / illustration below: Barcode scanner for Zone 1 hazardous areas)

Quickly printing out labels in hazardous system areas has so far been out of the question: there was no suitable protected hardware or protection concepts for standard devices. R. STAHL has come up with a solution: a regular printer inside an Ex p enclosure (pressurised enclosure).

This Ex-protection solution consists of a standard printer and a newly developed enclosure. With this solution, users can print in hazardous areas without any problems. The printed labels can simply be removed through a door at the front, without the printer having to be turned off. Additionally, the enclosure has a side door and a sliding floor with handle granting easy access for maintenance works.

This Ex p enclosure has further options for increased user-friendliness: for example, larger windows can be easily fitted, allowing a much better view of the display of the printer inside. The variable enclosure dimensions of this solution are another plus, as they can also encompass larger printers or labels.

Explosion-protected printing – overview of the advantages of the solution:

• For use in ATEX Zone 1/21 (Ex px) and 2/22 (Ex pz)
• The technical feasibility of special printers in Ex p enclosures can be tested at the customer's plant
• Fast and easy handling with one-hand operation
• Optional windows for full monitoring
• Sliding enclosure floor for easy maintenance

(Illustration above: complete Ex p printer solution for Zone 1, 2 / illustration below: easy label removal in hazardous area)

The use of mobile devices such as tablets or smartphones in hazardous areas require wireless data transmission. Our task was to install WLAN on the factory floor for a global player in the chemical industry. The biggest challenge was to toughen up a device meant for office use to be suitable for hazardous environments. The requirements were:

• Easy replacement of WLAN Access Points
• Easy connection of Ethernet cable
• Space for potential extensions with WirelessHART or LoRa
• Application at different locations worldwide with different Ex-requirements
   

With our network solution for ATEX Zone 1, the requirements were met with a minimal reduction in operability due to explosion protection considerations. The requirements listed above were realised as follows:

• The wireless access point was mounted on an extendible mounting plate
• The Ethernet cable was connected via a separate Ex e connection box with a special Ethernet terminal
• A large selection of different enclosure sizes
• Different explosion protection concepts to match the local specifications

For more information on Wi-Fi system solutions for Zone 1, click here:

For more information on Wi-Fi system solutions for Zone 2, click here:

For a description of HF isolators, click here:

(Illustration above: WLAN Access Point with Ex e / illustration below:

HF isolators when different antennae are used)

A customer's IT department specified the use of standard components, tried and tested for the safe area, for the explosion-protected connection of an oil rig to the internet. In order to meet this requirement, R. STAHL constructed a modular system from Ex d enclosures and explosion-protected splice cassettes that can be expanded and adjusted to the Wi-Fi requirements on the platform.

This specific Ex d solution uses optical fibre connected in our Ex op pr splice cassette (8186) for the connection to the switch. Other switches, two in this case, are connected via copper cables.

Additional enclosures with three switches each are in turn connected via optical fibre. The outgoing lines to the wireless local area networks access points are again made of copper, using a special Ethernet terminal for ATEX Zone 1 (8187).

For more information:

Ex d enclosures

Explosion-protected network technology