OPTICHECK technology built-in

State-of-the-art measuring devices combine robust measuring principles and powerful electronics to produce a wide range of readings and device-specific data. OPTICHECK technology built in leverages the features of the devices to translate their available comprehensive measuring system data into sophisticated diagnostics information for plant personnel. It goes beyond extensive device diagnostics, self-tests and on-site verification. With measurement principle-specific application diagnostics, this technology also allows in-depth insights into the process and thus opens up far-reaching possibilities for device monitoring, condition-based maintenance and optimisation of measurement technology and systems.

OPTICHECK technology built-in circuit board

The functional status of a measuring device can have a direct influence on the reliability of a measurement and therefore on process stability and system availability. The comprehensive device diagnostics from OPTICHECK technology built-in enable a measuring device to reliably detect typical errors or potential damage within the meter’s sensor or signal converter. OPTICHECK technology built-in produces a continuously repeating self-diagnosis of the measuring device resulting in reliable self-monitoring of the meter's health for every moment it is in operation.

Continuously repeating self-diagnosis

Every measuring device with OPTICHECK technology built-in is able to provide a reliable statement about the correct function of the device at any time. The technology uses continuously executed test routines to cyclically compare the current device condition against its baseline performance at time of delivery. In addition to the general monitoring of output signals, power supply and circuits, this includes numerous device-specific function tests.

Sensor and excitation coils short-circuit detection
Detection of mechanical damage to the primary measuring tube housing
Monitoring of measuring tube wear
- e.g. corrosion and abrasion monitoring of electrodes

Monitoring the measurement accuracy
- e.g. by feeding in test signals for continuous testing of the electronics

Continuous monitoring of integrated temperature and pressure measurements

Software and hardware errors detection
- e.g. disturbed piezo signal

Plausibility check of the measured value
- e.g. via continuous monitoring of the measuring range limits

Continuous evaluation of the signal quality
- e.g. to identify unfavourable installation conditions

Functional safety two employees on device

OPTICHECK technology built-in and SIL

OPTICHECK technology built-in offers particular added value during automated partial proof testing in safety-related applications. In the partial proof test, it enables a complete self-test to be carried out, which allows a proof test coverage (PTC) of up to 80% and a failure detection rate of approx. 95%, ensuring the safe operation of any safety-relevant function. This can also extend the interval between full tests under certain conditions.

On-site verification with report generation at the touch of a button

For the operator, the permanent self-monitoring is translated into standardised status signals in accordance with NAMUR NE 107. These status signals provide clear and comprehensible descriptions of the current device situation and provide a quick overview of error events. The error information can be immediately signalled to the control room via a defined error current or via error signals. This provides operators with condition-based information about the measuring devices in real time. Appropriate measures can be derived from this. All data is also logged in the measuring device and, in case of doubt, is available for a more in-depth root cause analysis.

The continuously running self-diagnosis of OPTICHECK technology built-in also forms the basis for rapid on-site verification of the measuring devices. Regardless of whether the status of software and hardware components is to be routinely checked and documented or carried out as part of troubleshooting, detailed verification reports on the health status of the instrumentation can be generated directly on site or in the control room. The measuring devices can be checked without interrupting the process and are ready for reporting at the touch of a button. Depending on the device type, this verification option can be performed wirelessly via Bluetooth using the OPTICHECK Mobile app on site at the field device or from the control room using the OPTICHECK DTM.

Built-in application diagnostics

In addition to comprehensive device diagnostics, OPTICHECK technology built-in stands for a wide range of device-specific application diagnostics that provide a deep insight into your own processes and systems. This measurement and device data is always available to operators to optimise and control processes. They also provide information that can be used for predictive system maintenance. OPTICHECK technology built-in utilises the device-specific data in numerous KROHNE measuring devices for meaningful application diagnostics.

Opticheck mobile smartphone infront of converter

Gas bubble detection in liquids
- e.g. for process control in applications with desired or undesired air inclusions
Detection of deposits in the measuring tube
- e.g. for the measurement of fatty media
Conductivity measurement
- e.g. for monitoring the quality of measured media (drinking water, etc.)
Process and ambient temperature changes
- e.g. to detect changes in the medium and temperature peaks outside the specification

Detection of process pressure changes
- e.g. to detect burner soot build-up in ovens for the purpose of planning furnace overhauls
Transition phase detection for steam, saturated steam, condensate
- e.g. for optimised control of steam circuits
Empty tube detection
- e.g. as an indicator of a faulty supply or defective pumps

Advantages of OPTICHECK technology built-in at a glance:

Provides a variety of integrated, sophisticated diagnostics for the reliable detection of typical damage to sensors and signal converters/transmitters
Continuously checks for hardware and software errors
Self-diagnoses the health status of measuring devices without process interruption
Produces meaningful diagnostic data for regular verification of field devices or for verification as part of a quick troubleshooting measure, directly on site or form the control room
Makes a verification report available at the touch of a button without the need to remove the device
Forms basis for predictive maintenance: recognises wear and maintenance requirements
Offers numerous application diagnostics for improved process reliability and system availability
Enables a safe failure fraction (SFF) of 94-96% and a partial proof test coverage of 80% in SIL applications
Can log and display trends over time for early detection of failures, such as electrode fouling, and provides detailed information for maintenance engineers to take effective preventative action