Smart Conduit Plug

Project Summary

Emerson transmitters are used in industrial control systems to measure manufacturing processes. Currently, when the control system indicates that a transmitter is reporting an out-of-range or error value, technicians must examine each transmitter on a panel to identify the source of the fault. The Smart Conduit Plug will be an add-on feature to Emerson temperature and pressure transmitters that allows technicians to visually identify in-range, out-of-range, and error states from a distance. This functionality decreases the time required for fault identification and the number of labor hours spent examining transmitters during routine maintenance.

Design Goal

The Smart Conduit Plug would offer a convenient way to upgrade device capabilities without complete replacement. The device will also offer insights for instrument health that will reduce maintenance and downtime caused by instrument failure.

Design Constraints

• Cost less than $30 per unit at scale of 10,000 units
• Be within the size specifications 2 inch X 2 inch x 2 inch external to the conduit entry
• Operate in ambient temperature ranges from –40°C to 85°C (-40°F to 185°F).
• Operate on power derived from the 4-20mA analog signal without disrupting the loop current.
• Not exceed a weight of 500 grams (1.1 pounds)
• Provide visual indication from 1.5-3 meters (5-10 feet) distance in daylight conditions
• Not inhibit the transmitter’s ability to withstand internal pressure up to 6895 kPa (1000 psi)
• Be able to be fully submersible in water to a depth of 2 meters (6.56 feet) for 1 hour.

• International Electrotechnical Commission - IEC 60079
• International Electromechanical Commission – IEC 60529
• Canadian Standards Associations - CSA C22.2
• Factory Mutual Approvals - FM3615
• National Pipe Thread - 1/2NPT
• Highway Addressable Remote Transducer (HART) Protocol