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
2015-10
How E+H instrumentation can improve process safety
Scope of presentation
Slide 2 Daniel Maglione, Endress+Hauser Flowtec
2015-10
What is safety?
How E+H instrumentation can improve process safety
Is this safety?
Slide 3 Daniel Maglione, Endress+Hauser Flowtec
2015-10
Safety is defined!
How E+H instrumentation can improve process safety
Slide 4 Daniel Maglione, Endress+Hauser Flowtec
2015-10
Safety
• Freedom from unacceptable risk
How E+H instrumentation can improve process safety
Reference: IEC 61511-1 Ed. 1.0, §3.2.67
Slide 5 Daniel Maglione, Endress+Hauser Flowtec
2015-10
Risk
• Combination of the frequency of occurrence of harm
and the severity of that harm
How E+H instrumentation can improve process safety
Reference: IEC 61511-1 Ed. 1.0, §3.2.64
Slide 6 Daniel Maglione, Endress+Hauser Flowtec
2015-10
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
How E+H instrumentation can improve process safety
Reference: IEC 61511-1 Ed. 1.0, §3.2.30
Slide 7 Daniel Maglione, Endress+Hauser Flowtec
2015-10
Tolerable risk
• Risk which is accepted in a given context
based on the current values of society
How E+H instrumentation can improve process safety
Reference: IEC 61511-1 Ed. 1.0, §3.2.89
Is this tolerable… … or this?
Slide 8 Daniel Maglione, Endress+Hauser Flowtec
2015-10
Hazard
• Potential source of harm
How E+H instrumentation can improve process safety
Reference: IEC 61511-1 Ed. 1.0, §3.2.31
Slide 9 Daniel Maglione, Endress+Hauser Flowtec
2015-10
Prevention
• Action that reduces the frequency of occurrence of a hazardous event
How E+H instrumentation can improve process safety
Reference: IEC 61511-1 Ed. 1.0, §3.2.52
Slide 10 Daniel Maglione, Endress+Hauser Flowtec
2015-10
Mitigation
• Action that reduces the consequence(s) of a hazardous event
How E+H instrumentation can improve process safety
Reference: IEC 61511-1 Ed. 1.0, §3.2.42
Slide 11 Daniel Maglione, Endress+Hauser Flowtec
2015-10
How E+H instrumentation can improve process safety
Scope of presentation
Slide 12 Daniel Maglione, Endress+Hauser Flowtec
2015-10
How E+H instrumentation can improve process safety
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?
Slide 13 Daniel Maglione, Endress+Hauser Flowtec
2015-10
How E+H instrumentation can improve process safety
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
Slide 14 Daniel Maglione, Endress+Hauser Flowtec
2015-10
How E+H instrumentation can improve process safety
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”
Slide 15 Daniel Maglione, Endress+Hauser Flowtec
2015-10
How E+H instrumentation can improve process safety
Layers of protection
Slide 16 Daniel Maglione, Endress+Hauser Flowtec
2015-10
How E+H instrumentation can improve process safety
Safety Instrumented System (SIS) standards
For manufacturers and suppliers of devices for SIS
For SIS designers, integrators and users
Slide 17 Daniel Maglione, Endress+Hauser Flowtec
2015-10
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)
How E+H instrumentation can improve process safety
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
Slide 18 Daniel Maglione, Endress+Hauser Flowtec
2015-10
How E+H instrumentation can improve process safety
Risk reduction by Safety Instrumented Systems R
isk
Initial Risk
SIL 1
SIL 2
SIL 3
SIL 4
Residual risk
Tolerable risk
Slide 19 Daniel Maglione, Endress+Hauser Flowtec
2015-10
Basic principle of an overall functional safety assessment
How E+H instrumentation can improve process safety
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)
Slide 20 Daniel Maglione, Endress+Hauser Flowtec
2015-10
How E+H instrumentation can improve process safety
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
Slide 21 Daniel Maglione, Endress+Hauser Flowtec
2015-10
How E+H instrumentation can improve process safety
Scope of presentation
Slide 22 Daniel Maglione, Endress+Hauser Flowtec
2015-10
Overview Endress+Hauser 2-wire platform
How E+H instrumentation can improve process safety
Levelflex Micropilot
Promass Prosonic Flow Promag Prowirl
Level
Flow
Slide 23 Daniel Maglione, Endress+Hauser Flowtec
2015-10
Promass 200 overview
How E+H instrumentation can improve process safety
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.
Slide 24 Daniel Maglione, Endress+Hauser Flowtec
2015-10
Promass 200 overview
How E+H instrumentation can improve process safety
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
Slide 25 Daniel Maglione, Endress+Hauser Flowtec
2015-10
Safety aspects for Endress+Hauser flowmeters
How E+H instrumentation can improve process safety
Safety by design (development) Safety by design (product)
State of the art production Functional Safety / SIL
Heartbeat TechnologyTM
Slide 26 Daniel Maglione, Endress+Hauser Flowtec
2015-10
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
How E+H instrumentation can improve process safety
Proline 200 – The green choice Power consumption: • Promass 83 ≤ 15 W • Promass 200 ≤ 0.77 W Saves electricity Reduced carbon footprint
Slide 27 Daniel Maglione, Endress+Hauser Flowtec
2015-10
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
How E+H instrumentation can improve process safety
Slide 28 Daniel Maglione, Endress+Hauser Flowtec
2015-10
Safety aspects for Endress+Hauser flowmeters
How E+H instrumentation can improve process safety
Safety by design (development) Safety by design (product)
State of the art production Functional Safety / SIL
Heartbeat TechnologyTM
Slide 29 Daniel Maglione, Endress+Hauser Flowtec
2015-10
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
How E+H instrumentation can improve process safety
Slide 30 Daniel Maglione, Endress+Hauser Flowtec
2015-10
Safety by design
• Second line of defense
• Dual seal
• Rated secondary containment
• Purge connections
• Rupture disk
How E+H instrumentation can improve process safety
Rupture disk
Predefined breaking point
Purge connections
Slide 31 Daniel Maglione, Endress+Hauser Flowtec
2015-10
Clear information – Proline 200 HMI
• Multiple HMI languages supported
• Diagnostic information and suggested remedies
How E+H instrumentation can improve process safety
Slide 32 Daniel Maglione, Endress+Hauser Flowtec
2015-10
Safety aspects for Endress+Hauser flowmeters
How E+H instrumentation can improve process safety
Safety by design (development) Safety by design (product)
State of the art production Functional Safety / SIL
Heartbeat TechnologyTM
Slide 33 Daniel Maglione, Endress+Hauser Flowtec
2015-10
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
How E+H instrumentation can improve process safety
Slide 34 Daniel Maglione, Endress+Hauser Flowtec
2015-10
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)
How E+H instrumentation can improve process safety
Slide 35 Daniel Maglione, Endress+Hauser Flowtec
2015-10
How E+H instrumentation can improve process safety
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
Slide 36 Daniel Maglione, Endress+Hauser Flowtec
2015-10
Safety aspects for Endress+Hauser flowmeters
How E+H instrumentation can improve process safety
Safety by design (development) Safety by design (product)
State of the art production Functional Safety / SIL
Heartbeat TechnologyTM
Slide 37 Daniel Maglione, Endress+Hauser Flowtec
2015-10
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
How E+H instrumentation can improve process safety
Heartbeat TechnologyTM
Final element (Actuator)
Logic solver Sensor
Slide 38 Daniel Maglione, Endress+Hauser Flowtec
2015-10
New Proline – Improved SFF and λdu values
How E+H instrumentation can improve process safety
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
Slide 39 Daniel Maglione, Endress+Hauser Flowtec
2015-10
New Proline – Reduced PFDavg levels
How E+H instrumentation can improve process safety
New Proline, e.g. Promass 200
160 FIT
73 FIT
State of the art so far, e.g. Promass 83
Slide 40 Daniel Maglione, Endress+Hauser Flowtec
2015-10
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
How E+H instrumentation can improve process safety
Reference: IEC 61511-1 Ed. 1.0, §3.2.58
In a factory calibration rig… …or using a mobile calibration rig
Slide 41 Daniel Maglione, Endress+Hauser Flowtec
2015-10
New Proline – Enabling prolonged proof test intervals
How E+H instrumentation can improve process safety
• 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
Slide 42 Daniel Maglione, Endress+Hauser Flowtec
2015-10
New Proline – Verification without process interruption
How E+H instrumentation can improve process safety
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
Slide 43 Daniel Maglione, Endress+Hauser Flowtec
2015-10
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
How E+H instrumentation can improve process safety
We want your plant to run safely and efficiently!
Safety measures should not unnecessarily hinder operations
Slide 44 Daniel Maglione, Endress+Hauser Flowtec
2015-10
How E+H instrumentation can improve process safety
“Increased safety at lower cost”
Slide 45 Daniel Maglione, Endress+Hauser Flowtec