Benefits of Endress+Hauser’s Level and Flow 2-wire ...

2017-09

Products Solutions Services

Benefits of Endress+Hauser’sLevel and Flow 2-wire portfoliofeaturing Heartbeat Technology

Slide 1 Daniel Maglione PCF & Stefan Jäger PCM

2017-09

Agenda

Benefits of Endress+Hauser’s Level and Flow 2-wire portfolio featuring Heartbeat Technology

Benefit of our 2-wire portfolio Safety by design

SIL made easy Heartbeat Technology


2017-09

Overview of Endress+Hauser’s 2-wire platform


Levelflex Micropilot

Promass Promag Prowirl

Level

Flow


2017-09

The installed base is growing…


Promass E 200 Levelflex FMP5xRelease 2010

Promass F 200Release: 07.2012

Promag P/H 200Release: 08.2012

Micropilot FMR5x Release: 12.2012

Prowirl F/R/D/O 200

Release: 11.2013

>300.000 pcs.


2017-09

Benefits from platform concept


“Uniform device concepts across

measurement parameters create

invaluable advantages!”

Voice of a market leader in the chemical industry


2017-09

Overview 2-wire platform


4-20mA + Status

Housing

4-20mA4-20mA

4-20mADC

4-20mAAC

PA +Status

Approval

Sensors

Electronics

ATEX

2-wire 4-wire

HistoROM+

FF +Status

mechanical buttons oroptical buttons for operation

from outside

Display

Remote DisplayFHX50

4-20mA –

PromassE/F 200

Promag P/H 200

Micropilot FMR5x

LevelflexFMP5x

Prowirl F/R/D/O 200

Plastic Alu 316L


2017-09

Identical accessories and spare parts for flow and level


• Reduce stock expenses due to uniform spare part concept


2017-09

Identical accessories and spare parts for flow and level

Support in finding the required spare part:

• Sticker on each official spare part with the

spare part number

• Sticker in each housing with a list of all

used parts (with spare part number) for

the individual instrument

• Spare Part Finding tool (online, free)


Sticker on the parts

Sticker with all spare parts inside the lid


2017-09

User oriented menu structure


Under operating conditionsTask oriented

OPERATOR

For commissioningFor troubleshooting

Task oriented

MAINTENANCE

Specific taskProblem solving

Functional oriented

EXPERT


2017-09


Setup wizard – guided, interactive, simple

Guided

• All relevant settings included in one sequence

• Step-by-step approach with direct feedback on completion

Interactive

• Dynamic page layout depending on individual settings

• Self adapting pictures and help text

Simple

• Fits nearly all commissioning jobs• Easy-to-use and intuitive


2017-09


Setup wizard – guided, interactive, simple


2017-09

Displays to fit your specific needs


Push button (SD02) Touch control (SD03)

• Mechanical push buttons

• HistoROM:Backup and copy of transmitter data

• IP20/NEMA1 mounted in the housing (without cover)

• Touch control (IR)

• HistoROM:Backup and copy of transmitter data

• Backlit display (white color) withRed color for alarm


2017-09

Benefits in the procurement phase


• Reduced coordination efforts - 10 to 50% of time

• Qualify only one supplier - 10 to 50% of time

• Reduced storage - 10 to 80% of costs

• Saved training efforts - 10 to 50% of costs

• Fast E-procurement (e.g. online shop…) - 5 to 70% of time

Reduce procurement efforts and save costs around the life cycle

Cost

Procurement/ Storage/ Training

Life cycle savings


2017-09

Benefits in the installation phase (cp. to Coriolis 4-wire)


When installing a Coriolis 2-wire flowmeter vs. a traditional

4-wire Coriolis flowmeter

• Statement from major European Chemical companies

• Total savings per installation point 400 – 1’000 EUR (*)

• Savings by:

• Reduced cabling and simplified installation

• Harmonized and simplified Ex installation (like level and pressure)

(*) level of savings depends on plant infrastructure


2017-09

HistoROM – it will never forget!


The HistoROM isfixed in the housing(can not be lost or“forgotten”)

• Functions HistoROM:• Storage of device parameters

• Storage of event log book (100 events)

• Together with on-site display:

• Backup of device settings in the display

• Restore of device settings from display backup file

• Import settings from device 1 to device 2 (e.g. same tank, same installation, same settings)

• Benefit:• Easy electronic exchange

• No need of SW – tooling or new setup to start measurement, only screw driver necessary

• History information for diagnostic purposes

• Safety for configuration data without SW–tooling, time saving full restore/backup

• Time saving setup of tank farms with import of settings from device to device


2017-09

HistoROM – easy electronic exchange


Electronic change during night shift

The HistoROM isfixed in the housing(can not be lost or“forgotten”)

Example HistoROM functionality


2017-09

Animation HistoROM



2017-09

HistoROM – savings while commissioning


• Time needed for commissioning of one measuring point 20 min

• Time needed for copy/paste of a measuring point 5 min(using the duplicate functionality of HistoROM)

• Example – commissioning of 60 identical tanks

• Traditional commissioning (1200 min @ 100 $/h) 2000 $

• When using HistoROM functionality (300 min @ 100 $/h) 500 $

• Savings using HistoROM 15 h/1500 $

Cost

Commissioningtime

Commissioning cost savings


2017-09

Chapter 2 – Safety by design





2017-09

Entire 2-wire platform follows same safety concept




Level

Flow


2017-09

Promass 200 overview


Promass 200

3. Promass 200Ideal flow meter for continuous process control offering a high level of safety and reliability. Improving process control by offering multivariable measurement.

2. Two-wireEasy integration, as per any other loop powered device; 4–20 mA HART, PFS, FF, PROFIBUS PA. Reducing complexity and standardizing integration.

1. World firstPromass 200 is the first two-wire Coriolis meter for mass flow and density measurement offering a real 4–20 mA loop-powered integration.


2017-09

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 150 °C (–40 to 302 °F) -50 to 205 °C (-58 to 401 °F)

Mass flow accuracy ±0.25% ±0.10%

Density accuracy 0.0005 g/cm3 0.0005 g/cm3

Pressure rated

sensor housingNo Yes


2017-09

Safety in 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


2017-09

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



2017-09

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



2017-09

Safety by design

• Second line of defense

• Dual seal

• Rated secondary containment

• Purge connections

• Rupture disk


Rupture disk

Predefined breaking point

Purge connections


2017-09


Certificates and compliance – Promass

• 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


2017-09

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


> 2’000’000 Electromagnetic> 500’000 Coriolis


2017-09

Extensive tests and services offering

• 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)



2017-09

Chapter 3 – SIL made easy





2017-09

• Hazard

• Harm

• Risk

• Tolerable risk


The red line of process safety

• Potential source of harm

• “When people get hurt”

• “Combination of likelihood of harm and its severity”

• “A risk level we can accept”

• The important question – “Can we accept the risk?”

• Yes No further actions necessary

• No How can we reduce the risk to the tolerable level?

Freedom from unacceptable risk Safety

By applying a Safety Instrumented System


2017-09


Layers of protection – do it right from the beginning


2017-09

Safety Instrumented System (SIS) risk reduction

• 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

4…20 mA

Communication

e.g. relay output

Final element(Actuator)

Logic solver

Sensor


2017-09


SIL levels and their corresponding risk reduction R

isk

SIL 1

SIL 2

SIL 3

SIL 4

Initial Risk

Residual risk

Tolerable risk


2017-09

Risk graph to determine required SIL level


/ Occupancy


2017-09


Redundancy improves risk reduction

Transmitter SIL 3 SIL 3 SIL 3Sensor SIL 2 SIL 2 SIL 2Flowmeter SIL 2 SIL 2 SIL 2

Installation SIL 2 capable SIL 3 capable

Single device Homogenous redundancy


2017-09


Safety Instrumented System (SIS) standards

For manufacturers and suppliers of devices for SIS

For SIS designers, integrators and users


2017-09

Basic principle of an overall functional safety assessment


Random failurese.g. resistor short-cut,

microcontroller stuck-at-1

Systematic faultse.g. specification faults, incorrect

maintenance, software bugs

Basically unavoidableDetection and control offailures during operation

Basically avoidableFault avoidance during development,

implementation and use

Technical measuresDiagnostics, fail safe, redundancy

Organizational measuresLessons learned, training

Reliability data(λ values, SFF, FIT, PFD, PFDavg)

Functional Safety Management (FSM)


2017-09

Reliability data – how to interpret?


λDU SFF PFD PFDavgFIT

How to understand and use these data?


2017-09

λ values (failure rates) and their relation to the SFF


SFF [%]Safe Failure Fraction

Safe &Detectable

Safe &Undetectable

Dangerous &Detectable

Dangerous &Undetectable


2017-09

λDU – What does it mean in practice?


The λDU value indicates how likely it is that the Safety Instrumented System has a Dangerous Undetected (DU) failure, resulting in that it cannot perform its intended safety function on demand

λDU


2017-09

How does λDU relate to the PFD value?


λDU – The likely number of DU failures during a time interval of 109 hours

Unit is “FIT” (Failures in Time), e.g. 500 FIT = 500 DU-failures/109 h

However, since 109 hours = 114 155 years, the FIT info is somewhat abstract

PFD – Probability of Failure on Demand

Directly linked to the λDU value

Also describes the reliability of the SIS to perform its desired function

Relates to the actual time frame the SIS is used

The PFD value is much more convenient to use than the λDU value


2017-09

SILPFD - Probability of

Failure on Demand

1 10-1 to 10-2

2 10-2 to 10-3

3 10-3 to 10-4

4 10-4 to 10-5


How does the SIL level relate to the PFD value?

• The entire system must be considered (sensor, logic solver & actuator)

Example:

Logic λDU

15%Actuator λDU

50%Sensor λDU

35%

Total λDU

Success Rate

>90%

>99%

>99.9%

>99.99%

Risk Reduction Factor

>10

>100

>1'000

>10'000


2017-09


How does the PFD chart relate to the SIL level?

SIL 2

SIL 3

SIL 1


Failure on Demand

1 10-1 to 10-2

2 10-2 to 10-3

3 10-3 to 10-4

4 10-4 to 10-5


2017-09


Safety instrumented system with λDU 1000 FIT

SIL 2

SIL 3

SIL 1

1000 FIT


2017-09


Less FIT lower PFD SIL level maintained longer

500 FIT

SIL 1

SIL 2

SIL 3

1000 FIT


2017-09

Proof test – revealing your undetected faults

Test performed to reveal undetected faults in a SIS so that, if necessary,

the system can be restored to its designed functionality


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

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

Option 1 - Functional test of the entire SIS

• Reach critical trigger point for the SIS (e.g. “flow too low” or “high level”) and make sure the actuator performs as defined (valve open or close)

Option 2 - Partial testing of the SIS

• Ensure functionality of an individual SIS component (e.g. sensor) by verifying that it fulfills its specified performance for the safety function


2017-09


Proof testing improves the PFD value

SIL 1

SIL 2

SIL 3

1000 FIT


2017-09



SIL 1

SIL 2

SIL 3

1000 FITSurprise… it is game time!• Promass 200: λDU = 73 FIT• 73 DU-failures in 114 155 years• Average expected DU-failures per year• = 73 / 114 155 / 2• = 3.2 x 10-4 = PFDavg (1 year)

• Avg. risk of a DU-failure happening today= 0.0000876%

• Equals to “1 in 1 141 550 risk”• ~ Picking 5 correct lottery numbers of 45• ~ Picking 1 correct number of 100

three times in a row• Lets play!


2017-09



SIL 1

SIL 2

SIL 3

PFDavg

PTC (Proof Test Coverage)Example shows 100% PTC

1000 FIT

Proof test(functional test of entire SIS)


2017-09


Summary – how to maintain SIL levels?

• Keep your λDU FITs low!

• Use instrumentation with

high diagnostic coverage

• Perform proof testing when the

PFD value reaches critical level

• A low λDU enables prolonged

proof test intervals

• Saves Time & Money!


2017-09

Chapter 4 – Heartbeat Technology





2017-09

Value of “SIL and Heartbeat Technology”


Heartbeat Verification complies withthe requirements for traceable verification

acc. to DIN EN ISO 9001:2008 – Section 7.6a

attested by TÜV-SÜDIndustrieservices GmbH


2017-09



Level

Flow

SIL & Heartbeat – Availability for 2-wire platform



2017-09

Heartbeat Technology overview


MonitoringVerificationDiagnostics

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


2017-09

Where are different faults/failures mainly located?


λ ~ 97-98%

λ ~ 2-3%

SIL calculationsonly address

Random failures

Systematic faultse.g. corrosion, abrasion, coating of measuring tubes

Random failurese.g. electronic component failure in transmitter


2017-09

Heartbeat Diagnostics


Traceable and redundant references

Voltage based(Electromagnetic)

Time based(Coriolis, Vortex, Ultrasonic)

Developedacc. to

IEC 61508

Diagnosticsacc. toNE 107


2017-09

Categorized and clear text diagnostic messages


• By categorizing device info according to NAMUR NE107the operator get direct information/instructions

Icon Status signal Examples of detailed information

[F] Failure Cause of failure device-internalor process-related

[C] Function check Change of configuration

[S] Out of specification Device being operated out of spec.

[M] Maintenance required Maintenance needed short-term

• The detailed diagnostic information indicates

• what happened

• remedy suggestions


2017-09


How do the “old” and “new” PFD values compare?

SIL 2

SIL 3

SIL 1Typical SIL capable flowmeterson the market, e.g. Promass 83or competitor devices

Promass 20073 FIT

160 FIT

Heartbeat continuously diagnoses whether failures have occurred. The scope of the diagnostics in the SIL mode corresponds to the SFF.

Heartbeat Verification

report


2017-09


More safety! Less effort! More flexibility!

SIL 2

SIL 3

SIL 1Promass 200 – 73 FIT

• Dedicated instrument design to achievehighest safety requirements

• Increased safety by best-in-class diagnostic coverage• Enabling prolonged proof-test intervals

Proof test(calibration of flowmeter)

Typical SIL capable flowmeters – 160 FIT

Example shows 100% PTC(~98% is more practical for flowmeters)


2017-09

• 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 withIEC 61511-1, Section 16.3.3

3rd party certified ISO 9001 compliant traceable verification


2017-09

Heartbeat Monitoring


Condition monitoring(of process and/or device)


2017-09

Level use cases


Build-up detection

Foam detection


2017-09


Safety life cycle and origin of failures

Specification44%

Changes after commissioning

20%Operations & maintenance

15%

Installations & commissioning

6%

Design & implementation

15%

IEC 61508 – Safety life cycle

Reference: HSE, UK, Control systems


2017-09

Users are aware of the risk due to systematic faults

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”


Main European based chemical company

• “Before we roughly had 75% Systematic faults

and 25% Random failures.

Thanks to a strong focus on FSM (including dedicated

trainings), we have reduced the amount of Systematic

faults significantly…. and now they are on the same

level as the Random failures.” Syste-matic

RandomSyste-matic

Random

Before

After


2017-09

Once again low λDU values & built-in verification pays off

Our offer

Low λDU values Enables user to proof test less often

Built-in verification 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



2017-09

Which of these would you choose for your SIS?


Promass 83F Promass F 200 VA flowmeter A piece of pipe

λDU 160 FIT 73 FIT 31 FIT 0 FIT

λDD + λSU + λSD 1727 FIT 4104 FIT 60 FIT 0 FIT

λTOT 1887 FIT 4177 FIT 91 FIT 0 FIT

SFF 92% 98% 66% “100% / NA”

MTBF 56 years 40 years 487 years ∞

Mass flow acc. 0.1% 0.1% 1.6% None

Proc. influence Low Low High None

Maintenance Low Low High None

Diagn./Monit. + ++ ~ None

Built-in verific. No Yes No No

Multivariable Yes Yes No No

• Random (electronics)

• Performance • Systematic faults


2017-09

It’s not all about who has the lowest λDU values!

The instrument selection decision will be based an a combination of:

• Safety, Availability, Functionality & Reliability

The user wants:

• The safest solution (λDU 0)

• To prolong his proof test intervals

• To have easy verification

• To minimize maintenance

• To measure accurate and reliable regardless of process conditions

• To have a device that is easy to operate and always works

Endress+Hauser strive to meet these

requirements in an optimal manner!



2017-09

Complete safety portfolio to fulfill individual needs


Best-in-classdiagnostics

Built-in verification

Condition monitoring

High reliability

Proof test services


2017-09

Conclusion





2017-09

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


2017-09


Thank you very much for your attention

Be safe!


2018-08


Improving plant safety & productivity with modern process instrumentation

An Endress+Hauser safety seminar

Slide 1 Daniel Maglione, Endress+Hauser

2018-08


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?


2018-08


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 plantReference: Risknowlogy, Functional Safety Certification Course


2018-08


Layers of protection – do it right from the beginning


2018-08


Safety Instrumented System (SIS) standards

For manufacturers and suppliers of devices for SIS

For SIS designers, integrators and users

84.00.01


2018-08


Safety Instrumented System (SIS) risk reduction

• 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

4…20 mA

Communication

e.g. relay output

Final element(Actuator)

Logic solver

Sensor


2018-08


SIL levels and their corresponding risk reduction R

isk

SIL 1

SIL 2

SIL 3

SIL 4

Initial Risk

Residual risk

Tolerable risk


2018-08


Voting – Find your optimal balance between safety and productivity


2018-08

Basic principle of an overall functional safety assessment


Random failurese.g. resistor short-cut,

microcontroller stuck-at-1

Systematic faultse.g. specification faults, incorrect

maintenance, software bugs

Basically unavoidableDetection and control offailures during operation

Basically avoidableFault avoidance during development,

implementation and use

Technical measuresDiagnostics, fail safe, redundancy

Organizational measuresLessons learned, training

Reliability data(λ values, SFF, FIT, PFD, PFDavg)

Functional Safety Management (FSM)


2018-08

Reliability data – how to interpret?


λDU SFF PFD PFDavgFIT

How to understand and use these data?


2018-08

λ values (failure rates) and their relation to the SFF


SFF [%]Safe Failure Fraction

Safe &Detectable

Safe &Undetectable

Dangerous &Detectable

Dangerous &Undetectable


2018-08

λDU – What does it mean in practice?


The λDU value indicates how likely it is that the Safety Instrumented System has a Dangerous Undetected (DU) failure, resulting in that it cannot perform its intended safety function on demand

λDU


2018-08

How does λDU relate to the PFD value?


λDU – The likely number of DU failures during a time interval of 109 hours

Unit is “FIT” (Failures in Time), e.g. 500 FIT = 500 DU-failures/109 h

However, since 109 hours = 114 155 years, the FIT info is somewhat abstract

PFD – Probability of Failure on Demand

Directly linked to the λDU value

Also describes the reliability of the SIS to perform its desired function

Relates to the actual time frame the SIS is used

The PFD value is much more convenient to use than the λDU value


2018-08


How does the SIL level relate to the PFD value?


Failure on Demand

1 10-1 to 10-2

2 10-2 to 10-3

3 10-3 to 10-4

4 10-4 to 10-5

• The entire system must be considered (sensor, logic solver & actuator)

Example:

Logic λDU

15%Actuator λDU

50%Sensor λDU

35%

Total λDU

Success Rate

>90%

>99%

>99.9%

>99.99%

Risk Reduction Factor

>10

>100

>1'000

>10'000


2018-08


How does the PFD chart relate to the SIL level?

SIL 2

SIL 3

SIL 1


Failure on Demand

1 10-1 to 10-2

2 10-2 to 10-3

3 10-3 to 10-4

4 10-4 to 10-5


2018-08


Safety instrumented system with λDU of 1000 FIT

SIL 2

SIL 3

SIL 1

1000 FIT


2018-08


Less FIT lower PFD SIL level maintained longer

500 FIT

SIL 1

SIL 2

SIL 3

1000 FIT


2018-08


Proof test – revealing your undetected faults

Test performed to reveal undetected faults in a SIS so that, if necessary,

the system can be restored to its designed functionality

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

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

Option 1 - Functional test of the entire SIS

• Reach critical trigger point for the SIS (e.g. “flow too low” or “high level”) and make sure the actuator performs as defined (valve open or close)

Option 2 - Partial testing of the SIS

• Ensure functionality of an individual SIS component (e.g. sensor) by verifying that it fulfills its specified performance for the safety function


2018-08



SIL 1

SIL 2

SIL 3

PFDavg

PTC (Proof Test Coverage)Example shows 100% PTC

1000 FIT

Proof test(functional test of entire SIS)


2018-08


Summary – how to maintain SIL levels?

• Keep your λDU FITs low!

• Use instrumentation with

high diagnostic coverage

• Perform proof testing when the

PFD value reaches critical level

• A low λDU enables prolonged

proof test intervals

• Saves Time & Money!


2018-08



Is the verification concept compliant with the requirements fortraceable verification acc. to DIN EN ISO 9001:2008 – Section 7.6a?

attested by TÜV-SÜD Industrieservices GmbH


2018-08

Heartbeat Technology overview


MonitoringVerificationDiagnostics

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


2018-08

Where are different faults/failures mainly located?


λ ~ 97-98%

λ ~ 2-3%

SIL calculationsonly address

Random failures

Systematic faultse.g. corrosion, abrasion, coating of measuring tubes

Random failurese.g. electronic component failure in transmitter


2018-08

Heartbeat Diagnostics


Traceable and redundant references

Voltage based(Electromagnetic)

Time based(Coriolis, Vortex, Ultrasonic)

Developedacc. to

IEC 61508

Diagnosticsacc. toNE 107


2018-08

Categorized and clear text diagnostic messages


• By categorizing device info acc. to NAMUR NE 107 direct information/instructions are given

Icon Status signal Examples of detailed information

[F] Failure Cause of failure device-internal or process-related

[C] Function check Change of configuration

[S] Out of specification Device being operated out of spec.

[M] Maintenance required Maintenance needed short-term

• The detailed diagnostic information indicates

• what happened & remedy suggestions


2018-08


How do the “old” and “new” PFD values compare?

SIL 2

SIL 3

SIL 1Typical SIL capable flowmeterson the market, e.g. Promass 83or other Coriolis brands

Promass 20073 FIT

160 FIT

Heartbeat continuously diagnoses whether failures have occurred. The scope of the diagnostics in the SIL mode corresponds to the SFF.


2018-08


More safety! Less effort! More flexibility!

SIL 2

SIL 3

SIL 1Promass 200 – 73 FIT

• Dedicated instrument design to achievehighest safety requirements

• Increased safety by best-in-class diagnostic coverage• Enabling prolonged proof-test intervals

Proof test(calibration of flowmeter)

Typical SIL capable flowmeters – 160 FIT

Example shows 100% PTC(~98% is more practical for flowmeters)


2018-08

Reduction of DU values

The diagnostic features of Heartbeat Technology (Promass, Promag, Prowirl 200)

offers higher SFF and lower DU values


Promass 83F

89,6 %

178 FIT

SFF Lambda DU

Promag 53P

76 %

295 FIT

SFF Lambda DU

Prowirl 72F

80 %

175 FIT

SFF Lambda DU

Promass F 200

98 %

73 FIT

SFF Lambda DU

Promag P 200

95 %

156 FIT

SFF Lambda DU

Prowirl F 200

98 %

70 FIT

SFF Lambda DU


2018-08



• 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 withIEC 61511-1, Section 16.3.3

3rd party certified ISO 9001 compliant traceable verification


2018-08

Heartbeat Monitoring


Condition monitoring(of process and/or device)


2018-08


Safety life cycle and origin of failures

Specification44%

Changes after commissioning

20%Operations & maintenance

15%

Installations & commissioning

6%

Design & implementation

15%

IEC 61508 – Safety life cycle

Reference: HSE, UK, Control systems


2018-08

Users are aware of the risk due to systematic faults


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”

Main European based chemical company

• “Before we roughly had 75% Systematic faults and 25% Random failures.

Systematic Random

Before

Systematic Random

After

• Thanks to a strong focus on FSM (including dedicated trainings),

we have reduced the amount of Systematic faults significantly…

and now they are on the same level as the Random failures.”


2018-08

Once again low λDU values & built-in verification pays off


Modern instrumentation

Low λDU values Enables user to proof test less often

Built-in verification 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


2018-08

It’s not all about who has the lowest λDU values!


The instrument selection decision will be based an a combination of:

• Safety, Availability, Functionality & Reliability

The user wants:

• The safest solution (λDU 0)

• To prolong his proof test intervals

• To have easy verification

• To minimize maintenance

• To measure accurate and reliable regardless of process conditions

• To have a device that is easy to operate and always works

These requirements should be balanced in an optimal manner!


2018-08

Consider both random failures and systematic faults in your SIS selection


Best-in-classdiagnostics

Built-in verification

Condition monitoring

High reliability

Proof test services


2018-08


Thank you very much for your attention

Be safe!


Benefits of Endress+Hauser’s Level and Flow 2-wire ...

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