Application of the Intrinsically Safe CHARMS

Modules for Project Savings

Session ID: 8-2387

Presenters

Not pictured : Klaus Erni

Introduction

Application of the Intrinsically Safe CHARMS Modules

Intrinsic Safety Basics IS CHARMSApplication of IS for DeltaV SystemsApplication of IS CHARMS

You Are All Familiar With Emerson’s Electronic Marshalling

ControllersVarious busses

Wireless I/O

Electronic Marshalling

Electronic Marshalling Structure & Definitions

Fast Facts– Electronic Marshalled I/O

Types– CHARMS available today

• AI 4-20 mA HART• AO 4-20 mA HART• DI NAMUR • DI 24 VDC Low Side• DO 24 VDC High Side• Thermocouple/mV• RTD• Voltage 0-10 VDC

Rules– 8 Base Plates per CIOC– 12 Terminal Blocks per Base

Plate– 96 CHARMS per CIOC– Install in Div 2 or Zone 2

CHARMS

CIOC Carrier

CIOC (Redundant)

Terminal Block

Base Plate

CHARM

Electronic Marshalling

Background on Hazardous LocationsAn area containing (or likely to contain) an ignitable concentration of flammable gas or vapor, where an electrical spark of sufficient power will cause an explosion.

HAZARDOUS

NOT HAZARDOUS

Oxidizer Fuel(Air) (Gas, Vapor or

Dust)

Energy(Thermal or Electrical)

Ex

Hazardous Location Explosion Triangle

All three must be present to cause an ignition

Basis for most protection methods

Eliminate one and the operation is safe

Class I; Division 1; Groups A,B,C,D; T6

Permitted Class

Permitted DivisionGas GroupsTemperature Class

Zone 1, Ex ib IIB T6

Gas GroupsTemperature Class

Type(s) of Protection

Hazardous Locations & Protection – Examples

Permitted Zone

Defined by FM & ANSI/ISA

Defined by IEC & CENELEC

Traditionally Zones have been

in Europe

Traditionally Divisions have been in the US

Intrinsic Safety – Methods of ProtectionIntrinsic Safety – Methods of Protection Methods of protection in hazardous environments

– Containment, e.g. Explosion Proof, Ex d• Contains an explosion (at the electronics) within an enclosure or housing;

prevents the explosion from propagating outside the enclosure to the process area

– Segregation, e.g. Purge/Pressurization, Ex p• Prevents the Oxidizer and Fuel from coming into contact with the electronics

– Prevention, e.g. Intrinsic Safety, Ex i (e.g. Ex ia, Ex ib, Ex ic)• Prevents the Energy at the electronics from being high enough to cause an

explosion Intrinsic Safety has emerged as the preferred method of protection

in most world areas

Protection Methods

Comparison of Protection Methods

An intrinsically safe circuit consists of the following:- Intrinsically Safe Equipment

- Interconnecting Wire- Associated Apparatus

IntrinsicallySafe

Equipment

Associated Apparatus

AssociatedApparatus

Intrinsic Safety: Basic Concept

Ignition Curves

• Intrinsically safe circuits operate below the minimum

ignition point during normal and abnormal operation

with a 50% safety factor

• Relevant standards• UL913• FM3610• CSA C22.2 No. 157• ISA 12.2.01• IEC 60079-11

Explosion Prevention Via Intrinsic Safety Intrinsic Safety “i”, example Ex ia

– Divisions 1, 2 / Zones 0, 1, 2

Intrinsic Safety Characteristics – A low power technique is used to limit voltage, current, and stored

energy to a level below the minimum required for ignition during both normal AND abnormal operation of the equipment under consideration.

Hazardous Area

VVRR LL

CC

Isc/Io

3x3x Voc/Uo

BarrierBarrier CableCable

+

-

When to use Intrinsic Safety

Intrinsic Safety circuits are used when field devices are located in hazardous environments; they protect the circuit by limiting the energy to the field devices.

Field devices can be located in hazardous environments that are rated – Zone 0, Zone 1, or Zone 2– Class I Division 1 or Class 1 Division 2

Protection levels for the circuits could be– Ex ia, Ex ib, or Ex ic

Circuits will have defined parameters for Voltage, Current, Power, Capacitance, and Inductance

When IS is not a Good Fit...When IS is not a Good Fit... Some plants are geographically dispersed meaning that the

presence of explosive hazards for any period of time is unlikely. Some plants do not have the possibility of explosive mixtures being

present If your customer already uses Explosive Proof methods, they are

unlikely to adopt IS in the same facility In North America, IS is not typically used.

– This is changing slowly. Some US plants with IS include• 3M • Bayer • BASF

Intrinsic Safety ProtectionIntrinsic Safety Protection

Lower initial cost Conduit not required; poured seals not

required Any suitable enclosure is acceptable in

Div 2 Reduced cost of ownership

(maintenance, calibration, repair) Use of simple apparatus offers

flexibility Suitable for all gasses Permits live maintenance; lowers cost

and increases safety Accepted globally

Can only be used for low power Cable parameters must be considered

for IS applications in loop proofing Perceived to be complex

Advantages Disadvantages

Intrinsic Safety Applications

NOTE: For Hazardous Environment applications, Intrinsic Safety is easier to understand and easier to apply; however, where Intrinsic Safety methods of protection will be applied, be sure that you have the proper experience, and please contact Pepperl+Fuchs or Emerson Intrinsic Safety experts

NOTE: Intrinsic Safety training and education is recommended and can be made available to you, please contact Pepperl+Fuchs or Emerson Intrinsic Safety experts

How to Achieve Intrinsic Safety with DeltaV

Numerous Options & Applications with Emerson DeltaV Traditional DeltaV I/O and external Pepperl+Fuchs IS modules

– M-Series– S-Series– Emerson Standard CHARMS I/O

Emerson IS CHARMS DeltaV SIS and external Pepperl+Fuchs IS modules

Via energy limiting devices, IS barriers, that limit energy in the circuit…

Hazardous Area

Intrinsic Safety “Apparatus” – Traditional

Associated Apparatus provides the protection Intrinsic Safety Approved Apparatus are the field devices

Approval Focus Area

ApprovedApparatus

ConnectingCable

AssociatedApparatus

DCS, e.g.DeltaV

Hazardous Area

Intrinsic Safety “Apparatus” – IS CHARMS Associated Apparatus provides the protection Intrinsic Safety Approved Apparatus are the field devices

Approval Focus Area

ApprovedApparatus

ConnectingCable

AssociatedApparatus

DCS, e.g.DeltaV

More details later in presentation!!

How to Achieve Intrinsic Safety with DeltaV

IS barriers can be external isolators

IS barriers can be embedded with DCS I/O as in the case of IS CHARMS

Via energy limiting devices, IS barriers, that limit energy in the circuit…

External IS Barriers IS CHARMS

Traditional IS modulesfrom Pepperl+Fuchs

IS CHARMSfrom Emerson

inside

External P+F IS Isolating Barriers

Only a few channels of IS neededOR

Customer preference for redundant, multi-channel traditional I/O cards in S-series

OR DetlaV SIS requires external IS barriers

OR Customer preference for external IS

barriers due to experience, spares, standard operating practice, etc.

OR Emerson has opted to sell M-series or

Ovation to the customer

Via energy limiting devices, IS barriers, that limit energy in the circuit…

Adding External IS Isolating Barriers to DeltaV or DeltaV SISDeltaV S-series

Hazardous Area

Intrinsic Safety with Traditional I/O

DeltaV M-series DeltaV S-series

Via energy limiting devices, IS barriers, that limit energy in the circuit…

Adding External IS Isolating Barriers to DeltaV or DeltaV SIS

Hazardous Area Hazardous Area

Intrinsic Safety with Traditional I/OVia energy limiting devices, IS barriers, that limit energy in the circuit…

Hazardous Area

Many wires!!Too much cabinet space

DeltaV S-series

Intrinsic Safety with Standard CHARMS I/OVia energy limiting devices, IS barriers, that limit energy in the circuit…

CHARMSDeltaV S-series External IS Barriers

Hazardous Area

Cables, labels, associated drawings, and installation/checkout in FAT can cost more than DCS I/O channel hardware or an external IS barrier/isolator.

Intrinsic Safety with Standard CHARMS I/OVia energy limiting devices, IS barriers, that limit energy in the circuit…

CHARMSDeltaV S-series External IS Barriers

Hazardous Area

Cables, labels, associated drawings, and installation/checkout in FAT can cost more than DCS I/O channel hardware or an external IS barrier/isolator.

Now IS CHARMs are Available

ControllersVarious busses

Wireless I/O

Electronic Marshalling

Intrinsic Safety & Emerson IS CHARMS

Makes it EASY!! Combines Emerson I/O CHARMS and Pepperl+Fuchs

Intrinsic Safety Barrier technologies into a single, small, integrated package … IS CHARMS

Associated Apparatus

inside

IS CHARMS – Integrated I/O & IS ProtectionIS CHARMS – Integrated I/O & IS Protection

inside

IS CHARMS

Fast Facts– I/O plus IS protection– IS protection plus galvanic isolation

Types– IS CHARMS available 4Q 2011

• AI 4-20 mA HART• AO 4-20 mA HART• DI NAMUR • DO 11V @45mA VDC High Side

– IS CHARMs available 3Q 2012• Thermocouple/mV• RTD

Rules– 8 Base Plates per CIOC– 12 Terminal Blocks per Base Plate– 96 IS CHARMS per CIOC– Install in Div 2 or Zone 2– Can mix Standard CHARMS Base Plates

with IS CHARMS Base Plates

CIOC CarrierCIOC (Redundant)

IS Terminal Block

IS Base Plate

IS CHARM

Intrinsic Safety with IS CHARMS I/OVia energy limiting devices, IS barriers, that limit energy in the circuit…

IS barriers built into IS CHARMS!!IS CHARMS

• Smaller Footprint • Less Design• Lower Project Costs• Long Term Benefits• Emerson Unique

DeltaV S-series

IS CHARMS replaces many wires with 2 wires!

Hazardous Area

Why the IS CHARMS Solution?Why the IS CHARMS Solution? Project Benefits

– Smaller cabinet footprint, than external IS barriers– Less Design– Fewer cabinets; smaller cabinets– Fewer drawings– Fewer wires to connect and label– Easy last minute project changes– Lowest Total Installed Cost

Long Term Customer Benefits– One warranty. One company responsible.– Falls under standard Emerson life cycle plan– Fewer points of failure (screw terminal reduction)– Highest availability with single point integrity– Fewer spares– Less maintenance and inspection requirements– Higher safety and availability

Emerson is unique in this offering; others cannot compete

IS CHARMS Replace IS Barriers

IS CHARMS

120 I/O

CONVENTIONAL

IS BARRIERS

120 I/O

Cost Comparison – Business Results Achieved

IS CHARMS Savings

Area of SavingsPer 144 AI I/O

(a cabinet)Per 1000 AI I/O

(7 cabinets)Per 144 DI I/O

(a cabinet)Per 1000 DI I/O

(7 cabinets)Hardware 29,897$ 207,619$ 15,470$ 107,432$

Labor 5,557$ 38,591$ 5,557$ 38,591$

Floor Space 9,000$ 62,500$ 9,000$ 62,500$

Savings 44,454$ 308,711$ 30,027$ 208,523$ (less any additional cost of IS CHARM relative to conventional I/O or Standard CHARM)

Cost Savings with IS CHARMS Cost Savings with IS CHARMS

IS CHARMS CONVENTIONAL

IS BARRIERS

Intrinsic Safety with DeltaV SIS I/O

DeltaV SISDeltaV S- or M-series

Via energy limiting devices, IS barriers, that limit energy in the circuit…

Adding External IS Isolating Barriers to DeltaV or DeltaV SIS

BPCS

Hazardous Area

SIS

Hazardous Area

Summary

Discussed Intrinsic Safety Basics Discussed Application of the Intrinsically Safe

CHARMS Modules for Project Savings Use of IS CHARMS reduces project cost and

improves safety

Questions??

Where To Get More Information Attend Short Course Session ID: 4-2391

“Intrinsic Safety Fundamentals & IS CHARMS” Attend Emerson DeltaV Roadmap Visit us in the exhibition hall for a live demos

www.pepperl-fuchs.us Order a Free:

Pepperl+Fuchs Interface

Technology

Engineer’s Guide

rschosker@us.pepperl-fuchs.com