How Instrumentation can increase Process safety How E+H instrumentation can improve process safety Fundamentals of process safety •American Institute of Chemical Engineers (AIChE)

2015-10

Products Solutions Services

How E+H instrumentation can improve process safety

With special focus on Coriolis flowmeters

Slide 1 Daniel Maglione, Endress+Hauser Flowtec

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Scope of presentation


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What is safety?


Is this safety?


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Safety is defined!



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Safety

• Freedom from unacceptable risk


Reference: IEC 61511-1 Ed. 1.0, §3.2.67


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Risk

• Combination of the frequency of occurrence of harm

and the severity of that harm


Reference: IEC 61511-1 Ed. 1.0, §3.2.64


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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 61511-1 Ed. 1.0, §3.2.30


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Tolerable risk

• Risk which is accepted in a given context

based on the current values of society


Reference: IEC 61511-1 Ed. 1.0, §3.2.89

Is this tolerable… … or this?


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Hazard

• Potential source of harm


Reference: IEC 61511-1 Ed. 1.0, §3.2.31


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Prevention

• Action that reduces the frequency of occurrence of a hazardous event


Reference: IEC 61511-1 Ed. 1.0, §3.2.52


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Mitigation

• Action that reduces the consequence(s) of a hazardous event


Reference: IEC 61511-1 Ed. 1.0, §3.2.42


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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

Reference: www.aiche.org

• Identify Where is the danger? • Quantify How big is it? • Qualify Is it acceptable? • Reduce Can it be controlled?


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Importance of process safety

• To protect:

• 1. People

• 2. Environment

• 3. Plant

• 4. Image

• 2’000’000 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


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List of major accidents in the process industry

• Chemical

• 1974: Flixborough, England. Chemical plant explosion, 28 dead

• 1976: Seveso, Italy. Release of dioxins, 3’000 pets/farm animals died,

70’000 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. 4’000-20’000 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”


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Layers of protection


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Safety Instrumented System (SIS) standards

For manufacturers and suppliers of devices for SIS

For SIS designers, integrators and users


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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)


Reference: IEC 61511-1 Ed. 1.0, §3.2.72

Process interface

Process interface

Communication

e.g. 4…20 mA

Communication

e.g. Relay output

Final element (Actuator)

Logic solver

Sensor


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Risk reduction by Safety Instrumented Systems R

isk

Initial Risk

SIL 1

SIL 2

SIL 3

SIL 4

Residual risk

Tolerable risk


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Basic principle of an overall functional safety assessment


Random failures (e.g. resistor short-cut,

microcontroller stuck-at-1)

Systematic faults (e.g. specification faults,

software bugs)

Basically unavoidable Objective: Detection and control of

failures during operation

Basically avoidable Objective: Fault avoidance

during development

Technical measures (Diagnostics, Fail safe, Redundancy)

Organizational measures

Reliability data (λ values, PFDavg, PFH, SFF)

Functional Safety Management (FSM)


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Safety life cycle and origin of failures

Specification 44%

Changes after commissioning

20% Operations & maintenance

15%

Installations & commissioning

6%

Design & implementation

15%

IEC 61508 – Safety life cycle

Reference: HSE, UK, Control systems


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Overview Endress+Hauser 2-wire platform


Levelflex Micropilot

Promass Prosonic Flow Promag Prowirl

Level

Flow


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Promass 200 overview


Promass 200

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.

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.

1. 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.


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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 1.4539 (904L) 1.4539 (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 0.0005 g/cm3 0.0005 g/cm3

Rated 2nd containment No Yes


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Safety aspects for Endress+Hauser flowmeters


Safety by design (development) Safety by design (product)

State of the art production Functional Safety / SIL

Heartbeat TechnologyTM


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Transmitter development

• Proline 200 – developed according to IEC 61508

• 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 83 ≤ 15 W • Promass 200 ≤ 0.77 W Saves electricity Reduced carbon footprint


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Sensor development using computer simulation

• Computer simulation brings flexibility to the development

• Past:

• 20-30 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 10’000 - 20’000 computer simulated designs

• Improved performance and application stability of flowmeter



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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 10204-3.1

• NACE MR0175 and MR0103

• Material selection (ambient)

• Complete exterior in 316L – Certified acc. to EN 10204-3.1

• Accessories

• Overvoltage protection

• Weather protection cover



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Safety by design

• Second line of defense

• Dual seal

• Rated secondary containment

• Purge connections

• Rupture disk


Rupture disk

Predefined breaking point

Purge connections


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Clear information – Proline 200 HMI

• Multiple HMI languages supported

• Diagnostic information and suggested remedies



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State of the art production

• ISO 9001 quality management system

• ISO 14001 environmental management system

• OHSAS 18001 occupational health and safety management system

• Kaizen continuous improvement program



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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 17025 accredited calibration rigs (±0.015%)

• Verified cleaning IEC/TR 60877, BOC (for oxygen service)



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Promass – Certificates and compliance

• CE mark, C-Tick

• Ex approval (ATEX, IECEx, CCSAUS, 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 15156-1, NACE MR0103

• EN 60529, IEC/EN 60068-2-6, IEC/EN 60068-2-31, EN 61010-1,

IEC/EN 61326

• NAMUR NE 21, 32, 43, 53, 80, 105, 107, 131, 132


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New Proline – SIL and Heartbeat TechnologyTM

• Increased safety by best-in-class diagnostic coverage

• Enabling prolonged proof-test intervals

• In-line verification without process interruption



Final element (Actuator)

Logic solver Sensor


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New Proline – Improved SFF and λdu values


New Proline e.g. Promass 200

Developed acc. to IEC 61508 Increased diagnostic coverage

Higher SFF & Lower λdu

State of the art so far* e.g. Promass 83

Proven in use acc. to IEC 61511

* Given values are typical for SIL approved flow meters from E+H as well as other major suppliers


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New Proline – Reduced PFDavg levels


New Proline, e.g. Promass 200

160 FIT

73 FIT

State of the art so far, e.g. Promass 83


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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


Reference: IEC 61511-1 Ed. 1.0, §3.2.58

In a factory calibration rig… …or using a mobile calibration rig


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New Proline – Enabling prolonged proof test intervals


• State of the art so far, e.g. Promass 83: Every 2nd year

• New Proline, e.g. Promass 200: Every 5th year

Example: Full sensor proof test (incl. calibration)

Both give roughly the same PFDavg level

New Proline enables 2.5 times longer proof test intervals

Proof test


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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

• Electronic quality reporting – safe and effortless • Documented proof of diagnostic checks

Verification report

in accordance with IEC 61511-1, Section 16.3.3


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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


We want your plant to run safely and efficiently!

Safety measures should not unnecessarily hinder operations


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“Increased safety at lower cost”


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Products Solutions Services

Thank you very much for your attention


How Instrumentation can increase Process safety How E+H instrumentation can improve process safety Fundamentals of process safety •American Institute of Chemical Engineers (AIChE)

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