Products Solutions Services. Safety by Design. Ask questions, get answers! Slide 1 06/15/2017. Ngo

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1 Products Solutions Services Safety by Design Ask questions, get answers! Slide 1

2 Hai-Thuy Industry Manager Oil & Gas Slide 2

3 Since 2005 working for Endress+Hauser Hai-Thuy Slide 3

4 Functional Safety Professional (TÜV certified) TÜV: functional safety for safety instrument system professionals (IEC61511) conducted by Risknowlogy 4 days training including 4 hour exam. Slide 4

5 Go home safely! Save lives and costs Prevent Safety by design Mitigate Slide 5

6 Filling blind Slide 6

7 Proof testing is mandatory, but how to avoid systematic failures? Main US based chemical company 2% of every time we have human intervention we create a problem Leading specialty chemical company 4% of all devices which are proof tested get damaged during re-installation Slide 7

8 Proof test scenario: Fill to High High level alarm How do you proof your device? Relay switching output Advantage: complete comprehensive Disadvantage Not safe Time and efforts Slide 8

9 Proof test scenario: Test device with a bucket of oil/water Alternative proof procedure: step Relay switching output Slide 9

10 Proof test scenario with Endress+Hauser: Safe from the control room Proof test via push button: Liquiphant FTL8x FTL5x (FEL85) (FEL57) Test cycle: 4s Nivotester FTL325P Nivotester FTL825 Simulation Slave devices tested via push button Output signal (4-20mA) Slide 10

11 Easy and convenient proof test on the tank 4% of all devices, which are proof tested, get damaged during re-installation!!! According to a study Chemical customer in Rotterdam. Of course, this does not happen in the Oil & Gas industry Slide 11

12 Proof testing without dismounting the device Not necessary to interrupt or manipulate the production process for partial proof test. Recommended proof test interval 12 years 3 years 2 years Slide 12

13 Key points of API th Edition 2012: Above ground storage tanks Introduction of Tank Category 1, 2, 3 Differences between AOPS and MOPS Independence of AOPS AOPS for new sites follow ANSI/ISA (IEC modified) Overfill Prevention Process Proof testing A HHLA sensor on a floating roof tank have to detect the oil, even if it is above floating roof. No wireless communication for AOPS Slide 13

14 Initial situation: H2S leakage Add picture Slide 14

15 Endress+Hauser solution Adapter spool piece from ANSI flange to special displacer flange More distance to ensure to be more accurate measurement (blocking distance) Existing bypass chamber from Displacer were reused (Full inspection by user, eg. Thickness test passed) Slide 15

16 Displacer (Torque Tube Type) prone to leak Slide 16

17 Endress+Hauser solution: e.g. new stilling wells Bypass chambers were renewed due to it s aging. (Existing bypass chambers were inspected by thickness test by user, and they did not passed.) Slide 17

18 Endress+Hauser solution: e.g. use existing stilling wells LIC Naphtha Splitter after ADU I/F O/H Receiver Boot of VDU FMP51-TCCCCBACC3AGJALJAZ1 Using existing bypass chamber from Displacer. Insulation is removed, due to photo taken during replacement. FMP55-TCCCCBCAAGKALJDZ1 Using existing bypass chamber from Displacer. Slide 18

19 Levelflex vs. Displacer Mechanical devices like displacers and floats are prone to failures and therefore cause a lot of maintenance. Go from mechanics to electronics: The save and cost saving solution 2 nd line of defense no leakage more safety No upper blocking distance. Independent of density changes. Less influence by buildup. Independent of foam. Less influence by corrosion. No moving parts. Interface (e.g. water-oil and Level measurement in one device. Two measurement in one with EOP Slide 19

20 Levelflex FMP54 Heavy duty under harsh conditions Special Features: 2 nd process containment (gas tight glass feedthrough) ceramic graphite Robust design and gas tight glass feedthrough -196 to +450 C (-320 to 840 F) Pressures up to 400 bar (5800 psi) High diffusion resistance using ceramic coupling and graphite seal Resistant against Superheated steam (ceramic seal) application in steam boilers acc. to EN12952/12953 FMP54 Slide 20 The gas tight feed-through prevents e.g. leakage of toxic media Highest Safety at High Pressure and High Temperature

21 Work Order Generated Electronic verification -As is 5 min Organize Tools Upload Verification 10 min 15 min 15 min 10 min W/O Get Permit Ops Sign Off Review Verification Results 5 min 30 min Maintenance travels to FT- 130 Travel back to shop 30 min 5 20 min Maintenance performs Verification Close work order and work permit 15 min 15 min Source: Enform (50% of Oil & Gas deaths related to driving) >155 minutes / meter Slide 21

22 Heartbeat Technology overview Diagnostics Verification Monitoring Reliable self-monitoring Continuous, built-in diagnostic functionality Broadest test coverage Quick, concise guidance in case of errors (NE 107) Compliant testing On-demand, effortless procedure Easy handling, no process interruption Electronic quality reporting Condition-based maintenance Permanent reading of process-related variables Impact assessment External trend analysis Slide 22

23 Heartbeat Self diagnostic and verification Self diagnostic Heartbeat diagnostics Verification Heartbeat verification Slide 23

24 How do the old and new PFD values compare? Heartbeat continuously diagnoses whether failures have occurred. The scope of the diagnostics in the SIL mode corresponds to the SFF. Typical SIL capable flowmeters on the market, e.g. Promass 83 or competitor devices 160 FIT SIL 1 Promass FIT PTC for Heartbeat Verification = 0% SIL 2 SIL 3 Slide 24

25 More safety! Less effort! More flexibility! Dedicated instrument design to achieve highest safety requirements Increased safety by best-in-class diagnostic coverage Enabling prolonged proof-test intervals Promass FIT SIL 1 Proof test (calibration of flowmeter) Typical SIL capable flowmeters 160 FIT Example shows 100% PTC (~98% is more practical for flowmeters) SIL 2 SIL 3 Slide 25

26 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 LIVE DEMO Slide 26

27 Once again low λ DU values & built-in verification pays off Our offer Low λ DU values Built-in verification Enables user to proof test less often No need to open the transmitter housing or make additional electrical connections User benefits Reduces the need for personnel to physically touch a device Less risk for systematic faults (SIS and availability gains) Increased safety More up-time Saves time Reduces cost Slide 27

28 Mitigate the hazard with rupture disks Mechanical assemblies with predictable failure modes E.g. in E+H Promass design Slide 28

29 What will happen in the distribution network? Slide 29

30 Heat loss leading to condensation and water hammer (Graphics courtesy TLV Euro-Engineering GmbH) Slide 30

31 Patented Vortex meter design offers robust and reliable measurement Stainless steel DSC-sensor Robust Temperature shock proven Immune against vibrations One spare part for all linesizes Patented! Proven more than times! Slide 31

32 The robust sensor! Robustness against waterhammer. Slide 32

33 Wet steam alarm and help functionality 80% steam quality Slide 33

34 Memosens technology reduced maintenance time in the filed The Memosens technology revolutionizes the safety of data transfer by digitalizing the measured value in the sensor and transferring it to the transmitter without a contacting, and thus moisture-sensitive, connection. Slide 34

35 Memosens digital sensors with integrated data storage Benefits Non-contacting and digital signal transmission independent of moisture Lab calibration possible reduced time in the field Cost saving Slide 35

36 Memosens calibration concept for process sensors Slide 36

37 Memosens reduced time in the field Slide 37

38 Why laboratory calibration? Argument 1: Calibration in the field can be inconvenient or even dangerous while a simple sensor exchange is easy to do. Safety argument Slide 38

39 Test center facility of Endress+Hauser Slide 44

40 Go home safely! Save lives and costs Prevent Safety by design Mitigate Slide 45