Endress+Hauser's Heartbeat Technology in Sensors

Endress+Hauser Digital Transformation in Sensors: Heartbeat Technology Field measurement instruments are increasingly equipped with fault diagnosis capabilities that provide a high degree of reliability. This fault diagnosis capability not only detects malfunctions in the field device itself, but can also provide insights into process conditions and their potential effects on the device or related facility assets. The development of modern field measurement instruments delivers benefits far beyond the scope of primary measurement objectives through fault diagnosis, on-site device validation, and monitoring functions. Process sensors fulfill the primary purpose of process automation by providing characteristic measurements such as flow, level, pressure, temperature, conductivity, or pH value. Modern sensors also offer comprehensive features to monitor their own condition during operation. Beyond measuring parameter values, it is also necessary to meet industrial requirements and contribute to corrective facility maintenance. During their digital transformation, modern field measurement instruments have been equipped with comprehensive diagnostic capabilities. The integrated heartbeat technology software was developed to enable devices to self-monitor, self-validate, and perform fault diagnosis. Monitoring the overall condition of field devices has become a key parameter. Faults that have an adverse effect on device performance can now be tracked throughout the device's lifespan. This provides user guidance in case of device failure and attempts to detect faults before they occur through comprehensive fault diagnosis capabilities. The heartbeat technology also contributes by providing comprehensive validation routines. In this way, all defined functions of the device are tested. Since validation can be performed on-site and without process interruption, high confidence in measurement point performance is achieved while minimizing the impact on operations. Information obtained from each device validation is stored on the device or in higher-level systems according to NAMUR-NE107 standards and can be easily evaluated. This step enables transition from comparative static evaluations to continuous ones, including condition-based or predictive support. Heartbeat technology intelligently combines fault diagnosis, validation, and monitoring functions to ensure safe and cost-effective operation throughout the facility's entire lifecycle.

In summary, this process consists of two stages:

1. Measurement and control 2. Monitoring and optimization In the monitoring and optimization stage, digital information platforms allow long-term use of such data process models throughout the device lifecycle, thereby creating valuable data. In this way, process information can be generated in a clear and reproducible manner. This not only makes it easier to understand and optimize the process of a single device, but also enables access to the information obtained for similar use cases. As a result, the system delivers greater output, aids in identifying used and unused resources, and thus provides cost optimization. Furthermore, after focusing on detecting and evaluating errors in the measurement device itself, it will provide information on how the device's process performance can be understood and improved, thereby supporting the user in process optimization and predictive maintenance. The primary task of a field measurement instrument is, of course, to determine the measured variable of interest to the user and share it with the higher-level system using data communication. Beyond that, the technology of a field measurement instrument (as explained above) offers a wide range of diagnostic parameters; for example, corrosion, wear detection, surface internal coating index, foam detection, usage condition indices that indicate presence—can be concentrated into user-friendly information.

How? Let us explain with an example:

Foam Detection Feature

The advanced fault diagnosis function of the Micropilot can detect foam. It uses the correlation between attenuation in device ecogenicity and increasing foam density. Generally, foam formation is reduced by spraying from above. For effective control of this application, it is important to know whether foam is forming in the process and, if possible, how much is forming. Otherwise, uncontrolled foam buildup can damage process equipment or require cleanup after overflow. In the Micropilot, foam detection is performed by defining a fixed zone in the working area. This is necessary so that the correlation between foam thickness and ecogenicity can be evaluated independently of level. On the other hand, a lower limit value is also set for the amplitude of the level signal. This value is also an indicator of the maximum tolerable foam thickness. If the value from the process falls below the defined limit point, the spraying system can be activated using the output from the advanced fault detection function. Basically, there are two methods to control this function. In the first method, programming is performed using the advanced fault detection function within the device. Alternatively, it can be done in the PLC. In this case, with the fault detection signal provided by the device, the system is both protected and downtime is reduced to minimum levels, while chemical use is optimized and facility operating costs are reduced.