How E+H instrumentation can improve process safety

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Hugo Cobb
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1 Products Solutions Services How E+H instrumentation can improve process safety With special focus on Coriolis flowmeters Slide 1

2 Scope of presentation Slide 2

3 What is safety? Is this safety? Slide 3

4 Safety is defined! Slide 4

5 Safety Freedom from unacceptable risk Reference: IEC Ed. 1.0, Slide 5

6 Risk Combination of the frequency of occurrence of harm and the severity of that harm Reference: IEC Ed. 1.0, Slide 6

7 Harm Physical injury or damage to the health of people, either directly or indirectly, as a result of damage to property or to the environment Reference: IEC Ed. 1.0, Slide 7

8 Tolerable risk Risk which is accepted in a given context based on the current values of society Is this tolerable or this? Reference: IEC Ed. 1.0, Slide 8

9 Hazard Potential source of harm Reference: IEC Ed. 1.0, Slide 9

10 Prevention Action that reduces the frequency of occurrence of a hazardous event Reference: IEC Ed. 1.0, Slide 10

11 Mitigation Action that reduces the consequence(s) of a hazardous event Reference: IEC Ed. 1.0, Slide 11

12 Scope of presentation Slide 12

Understand hazards and risk 3. Manage risk 4.

13 Fundamentals of process safety American Institute of Chemical Engineers (AIChE) has defined the four pillars of process safety : 1. Commit to process safety 2. Understand hazards and risk 3. Manage risk 4. Learn from experience Identify Quantify Qualify Reduce Where is the danger? How big is it? Is it acceptable? Can it be controlled? Reference: Slide 13

14 Importance of process safety To protect: 1. People 2. Environment 3. Plant 4. Image people die from work related accidents every year Accidents are not tolerated by society! You think safety is expensive, try an accident An accident costs at least 10-20x more than to build the plant Reference: Risknowlogy, Functional Safety Certification Course Slide 14

15 List of major accidents in the process industry Chemical 1974: Flixborough, England. Chemical plant explosion, 28 dead 1976: Seveso, Italy. Release of dioxins, pets/farm animals died, animals were slaughtered (to ensure safe food chain). European Community issued the Seveso Directive regulations 1984: Bhopal, India. Runaway reaction induced venting of a tank containing poisonous methyl isocyanate. Est dead Oil & Gas 1988: Piper Alpha platform, North Sea. Explosion and resulting fire, 167 dead. Economical impact US$3.4 billion 2005: Texas City Refinery, US. Knockout drum overfilling led to escape of hydrocarbons which were ignited by a running diesel truck, 15 dead 2010: Deepwater Horizon platform, Gulf of Mexico. Explosion and fire led to a massive oil spill, 11 dead. Reference: Wikipedia List of industrial disasters Slide 15

16 Layers of protection Slide 16

17 Safety Instrumented System (SIS) standards For manufacturers and suppliers of devices for SIS For SIS designers, integrators and users Slide 17

18 Safety Instrumented System (SIS) Instrumented system used to implement one or more safety instrumented functions. An SIS is composed of any combination of sensor(s), logic solver(s), and final elements(s) Sensor Communication e.g ma Communication e.g. Relay output Final element (Actuator) Process interface Logic solver Process interface Reference: IEC Ed. 1.0, Slide 18

19 Risk How E+H instrumentation can improve process safety Risk reduction by Safety Instrumented Systems Initial Risk SIL 1 SIL 2 Tolerable risk SIL 3 SIL 4 Residual risk Slide 19

20 Basic principle of an overall functional safety assessment Systematic faults (e.g. specification faults, software bugs) Random failures (e.g. resistor short-cut, microcontroller stuck-at-1) Basically avoidable Objective: Fault avoidance during development Basically unavoidable Objective: Detection and control of failures during operation Organizational measures Technical measures (Diagnostics, Fail safe, Redundancy) Functional Safety Management (FSM) Reliability data (λ values, PFD avg, PFH, SFF) Slide 20

21 Safety life cycle and origin of failures IEC Safety life cycle Specification 44% Design & implementation 15% Installations & commissioning 6% Operations & maintenance 15% Changes after commissioning 20% Reference: HSE, UK, Control systems Slide 21

22 Scope of presentation Slide 22

23 Overview Endress+Hauser 2-wire platform Levelflex Level Micropilot Promass Promag Flow Prowirl Prosonic Flow Slide 23

loop-powered integration. 2. Two-wire Easy integration, as per any other loop powered device; 4 20 ma HART, PFS, FF, PROFIBUS PA.

24 Promass 200 overview Promass World first Promass 200 is the first two-wire Coriolis meter for mass flow and density measurement offering a real 4 20 ma loop-powered integration. 2. Two-wire Easy integration, as per any other loop powered device; 4 20 ma HART, PFS, FF, PROFIBUS PA. Reducing complexity and standardizing integration. 3. Promass 200 Ideal flow meter for continuous process control offering a high level of safety and reliability. Improving process control by offering multivariable measurement. Slide 24

4539 (904L); Alloy C22 Process temperature -40 to 140 C ( 40 to 284 F) -50 to 200 C (-58 to 392 F)

25 Promass 200 overview Promass E 200 Promass F 200 Sensor design Bent dual tube Slightly bent dual tube Line size DN 08 to 50 (3/8 to 2 ) DN 08 to 80 (3/8 to 3 ) Measuring tube (904L) (904L); Alloy C22 Process temperature -40 to 140 C ( 40 to 284 F) -50 to 200 C (-58 to 392 F) Mass flow accuracy ±0.25% ±0.10% Density accuracy g/cm g/cm 3 Rated 2 nd containment No Yes Slide 25

26 Safety aspects for Endress+Hauser flowmeters Safety by design (development) Safety by design (product) State of the art production Functional Safety / SIL Heartbeat Technology TM Slide 26

Transmitter development Proline 200 developed according to IEC 61508 Best-in-class diagnostics coverage

supported) Flexible access in the field.

27 Transmitter development Proline 200 developed according to IEC Best-in-class diagnostics coverage Reliable and safe (see SIL chapter) SIL 2/3 Intrinsically safe explosion protection Ex ia (also Ex d is supported) Flexible access in the field. Housing can be opened even in Ex areas Proline 200 The green choice Power consumption: Promass W Promass W Saves electricity Reduced carbon footprint Slide 27

28 Sensor development using computer simulation Computer simulation brings flexibility to the development Past: prototypes physically built/tested/iterated until success Present: 1. Simulate flowmeter design in computer (FEM, FVM) 2. Find robust optimum (consider pressure, temperature, vibration, etc ) 3. Build physical prototype, test and fine tune in lab 4. Iterate point 1-3 until success Best of typically computer simulated designs Improved performance and application stability of flowmeter Slide 28

29 Safety aspects for Endress+Hauser flowmeters Safety by design (development) Safety by design (product) State of the art production Functional Safety / SIL Heartbeat Technology TM Slide 29

Safety by design Industry related norms and certification NAMUR, PED, AD2000, CRN, KHK, Marine (GL, ABS, LR, BV, DNV, RMRS) Material selection (process) Stainless steel, Alloy C22, Ti, Zr, Ta

30 Safety by design Industry related norms and certification NAMUR, PED, AD2000, CRN, KHK, Marine (GL, ABS, LR, BV, DNV, RMRS) Material selection (process) Stainless steel, Alloy C22, Ti, Zr, Ta Certified acc. to EN NACE MR0175 and MR0103 Material selection (ambient) Complete exterior in 316L Certified acc. to EN Accessories Overvoltage protection Weather protection cover Slide 30

31 Safety by design Second line of defense Dual seal Rated secondary containment Purge connections Rupture disk Purge connections Rupture disk Predefined breaking point Slide 31

32 Clear information Proline 200 HMI Multiple HMI languages supported Diagnostic information and suggested remedies Slide 32

33 Safety aspects for Endress+Hauser flowmeters Safety by design (development) Safety by design (product) State of the art production Functional Safety / SIL Heartbeat Technology TM Slide 33

system OHSAS 18001 occupational health and safety

34 State of the art production ISO 9001 quality management system ISO environmental management system OHSAS occupational health and safety management system Kaizen continuous improvement program Slide 34

35 Promass Tests and services offer PMI test Certified weld tests according to EN, ASME (B31.3 & VIII), NORSOK Pressure test 1.5x nominal process pressure) ISO accredited calibration rigs (±0.015%) Verified cleaning IEC/TR 60877, BOC (for oxygen service) Slide 35

36 Promass Certificates and compliance CE mark, C-Tick Ex approval (ATEX, IECEx, C CSA US, NEPSI, TIIS, INMETRO, KTL, PESO, EAC, EXPLOLABS and other local approvals) 3A, EHEDG, FDA SIL 2/3 (IEC 61508) FF, Modbus and PROFIBUS DP/PA certification PED, AD2000, CRN, KHK, Marine (GL, ABS, LR, BV, DNV, RMRS) NACE MR0175/ISO , NACE MR0103 EN 60529, IEC/EN , IEC/EN , EN , IEC/EN NAMUR NE 21, 32, 43, 53, 80, 105, 107, 131, 132 Slide 36

37 Safety aspects for Endress+Hauser flowmeters Safety by design (development) Safety by design (product) State of the art production Functional Safety / SIL Heartbeat Technology TM Slide 37

38 New Proline SIL and Heartbeat Technology TM Increased safety by best-in-class diagnostic coverage Enabling prolonged proof-test intervals In-line verification without process interruption Heartbeat Technology TM Sensor Logic solver Final element (Actuator) Slide 38

to IEC 61511 * Given values are typical for SIL approved flow meters from E+H as

39 New Proline Improved SFF and λ du values State of the art so far* e.g. Promass 83 New Proline e.g. Promass 200 Proven in use acc. to IEC * Given values are typical for SIL approved flow meters from E+H as well as other major suppliers Developed acc. to IEC Increased diagnostic coverage Higher SFF & Lower λ du Slide 39

40 New Proline Reduced PFD avg levels 160 FIT State of the art so far, e.g. Promass FIT New Proline, e.g. Promass 200 Slide 40

restored to its designed functionality In a factory calibration rig

41 Proof test Test performed to reveal undetected faults in a safety instrumented system so that, if necessary, the system can be restored to its designed functionality In a factory calibration rig or using a mobile calibration rig Reference: IEC Ed. 1.0, Slide 41

42 New Proline Enabling prolonged proof test intervals Example: Full sensor proof test (incl. calibration) State of the art so far, e.g. Promass 83: New Proline, e.g. Promass 200: Every 2 nd year Every 5 th year Both give roughly the same PFD avg level New Proline enables 2.5 times longer proof test intervals Proof test Slide 42

need to interrupt process Activated via HMI or higher level systems Verification report Electronic quality

43 New Proline Verification without process interruption Heartbeat Diagnostics Continuous diagnostic checks (built-in) Coverage in SIL mode corresponds to the SFF (~98%) Heartbeat Verification On-demand, in-line, no need to interrupt process Activated via HMI or higher level systems Verification report Electronic quality reporting safe and effortless Documented proof of diagnostic checks in accordance with IEC , Section Slide 43

to ensure reliability and availability Safety measures should not

44 Endress+Hauser: Safety by choice not by chance Identify best technology to serve your application in an optimal way Select right materials and sizing to ensure reliability and availability Safety measures should not unnecessarily hinder operations We want your plant to run safely and efficiently! Slide 44

45 Increased safety at lower cost Slide 45

46 Products Solutions Services Thank you very much for your attention Slide 46

Safety in the process industry

Products Solutions Services Safety in the process industry Simply reliable Table of contents Endress+Hauser: At home in the process safety Smart devices and concepts for hazardous areas Introduction to