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TRANSCRIPT
07/05/2016
Products Solutions Services
Heartbeat TechnologyTM
The Pulse of Your Measurements
Slide 1 Seou Wei
07/05/2016
Challenges in the Process Industry …
Functional safety: High costs and constraints for periodic maintenance
Utility accounting: Keep up trust in the
integrity of measurements
Corrosion inside the measuring tube of a Coriolis flowmeter
?
Welcome to Heartbeat Technology!
Slide 2 PC Flowtec Marketing
07/05/2016
What Heartbeat Technology can do …
Heartbeat Diagnostics: Greatly reduced risk of failure
Heartbeat Verification: Clarity and evidence without
process interruption
Heartbeat Monitoring of process-related
parameters
Welcome to Heartbeat Technology!
Slide 3 PC Flowtec Marketing
07/05/2016
What‘s in it for you …
Full flexibility to schedule proof-tests,
enables cost savings
Proof of functional reliability, no discussion about the bill
Informed decisions about flowmeter maintenance
Welcome to Heartbeat Technology!
Slide 4 PC Flowtec Marketing
07/05/2016
Proline launch conference 2016: On the evolution of Functional Safety
Layers of protection – Do it right from the beginning
Slide 5 Daniel Maglione, Flowtec
07/05/2016
Basic principle of an overall functional safety assessment
Proline launch conference 2016: On the evolution of Functional Safety
Random failures e.g. resistor short-cut,
microcontroller stuck-at-1
Systematic faults e.g. specification faults, incorrect
maintenance, software bugs
Basically unavoidable Detection and control of failures during operation
Basically avoidable Fault avoidance during development,
implementation and use
Technical measures Diagnostics, fail safe, redundancy
Organizational measures Lessons learned, training
Reliability data (λ values, SFF, FIT, PFD, PFDavg)
Functional Safety Management (FSM)
Slide 6 Daniel Maglione, Flowtec
07/05/2016
Simply reliable: Safety in the process industry
Something to think about…
• Analysis of 34 incidents, based on 56 causes identified
Source: HSE - UK
07/05/2016
Heartbeat Diagnostics
• By categorizing device info according to NAMUR NE107 the operator get direct information/instructions
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
Slide 8
07/05/2016
Onboard diagnostics – running in the background
Heartbeat Technology Outlook
Continuous automatic internal check in the device
• Logic program run
control
• Reference pulse HF
• Quartz synchronization
• Measuring cycle time
• Supply voltage
• Temperature
• Check sum RAM
• Cable breakage
Check
• Continuous self-monitoring to check the correct functionality of the device • More than 80 diagnostic measures and techniques permanently running in the
background
Slide 9 D. Haag
07/05/2016
Reliability data – How to interpret?
Proline launch conference 2016: On the evolution of Functional Safety
λDU SFF PFD PFDavg
FIT
How to understand and use these data?
Slide 10 Daniel Maglione, Flowtec
07/05/2016
λ values (failure rates) and their relation to the SFF
Proline launch conference 2016: On the evolution of Functional Safety
SFF [%] Safe Failure Fraction
Safe & Detectable
Safe & Undetectable
Dangerous & Detectable
Dangerous & Undetectable
Slide 11 Daniel Maglione, Flowtec
07/05/2016
λDU – What does it mean in practice?
Proline launch conference 2016: On the evolution of Functional Safety
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
Slide 12 Daniel Maglione, Flowtec
07/05/2016
How does λDU relate to the PFD value?
Proline launch conference 2016: On the evolution of Functional Safety
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
Slide 13 Daniel Maglione, Flowtec
07/05/2016
Proline launch conference 2016: On the evolution of Functional Safety
How does the PFD chart relate to the SIL level?
SIL 2
SIL 3
SIL 1
Slide 15 Daniel Maglione, Flowtec
07/05/2016
Proline launch conference 2016: On the evolution of Functional Safety
Proof testing improves the PFD value
SIL 1
SIL 2
SIL 3
1000 FIT 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 1 correct number of 100
three times in a row • Lets play!
Slide 16 Daniel Maglione, Flowtec
07/05/2016
Proof test requirements - Standards and Regulations
Tuning forks – THE device for overfill prevention
Point level detection in Safety Instrumented Systems (SIS) require periodical proof tests, therefore different requirements respectively demands exist.
• Based on calculations as per IEC standards
• Based on national laws, standards or recommendations e.g.
• Operational safety regulations
• API2350 (Overfill Protection for Storage Tanks in Petroleum Facilities, American Petroleum Institute, USA)
• ISA 84.1 (Instrumentation, Systems, and Automation Society, USA)
• WHG (Water Resources Law, Germany)
• Buncefield report (published Recommendations on the design and operation of fuel storage sites)
• …
Slide 17 P. Borggreve
07/05/2016
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 18 Daniel Maglione, Endress+Hauser Flowtec
07/05/2016
Tuning forks – THE device for overfill prevention
Proof test according IEC 61508
• Part 4 § 3.8.5 proof test
periodic test performed to detect failures in a safety-related system
so that, if necessary, the system can be restored to an “as new”
condition or as close as practical to this condition
PF
Dav
g
Time [years]
0
0,002
0,004
0,006
0,008
0,01
0,012
0,014
0,016
0,018
0,02
0 3 6 9 12
Slide 19 P. Borggreve
07/05/2016
Proof test according IEC 61511
• Part 1 § 16.3.1 Proof testing
Periodic proof test shall be conducted using a written procedure to reveal
undetected faults that prevent the SIS from operating in accordance with
the safety requirement specification
Proof Testing
Slide 20 Seou Wei
07/05/2016
Proof test – Revealing your undetected faults
Test performed to reveal undetected faults in a
safety instrumented system so that, if necessary,
the system can be restored to its designed functionality
Proline launch conference 2016: On the evolution of Functional Safety
Reference: IEC 61511-1 Ed. 1.0, §3.2.58
In a factory calibration rig…
Slide 21 Daniel Maglione, Flowtec
07/05/2016
Total Proof test coverage according to IEC 61508
Total coverage (DC+PTC)
FTL80/81/85+ FTL825
Wet test 99% (Procedure IA MAX/MIN)
Simulation (in situ testing!)
97 % (Procedure IB) Via test button
Max
Min
Simply reliable: Safety in the process industry
Smart proof testing procedures reduce effort, increase safety and minimize shut down times.
07/05/2016
Proline launch conference 2016: On the evolution of Functional Safety
Proof testing improves the PFD value
SIL 1
SIL 2
SIL 3
PFDavg
PTC (Proof Test Coverage) Example shows 100% PTC (~98% is more practical)
1000 FIT
Slide 23 Daniel Maglione, Flowtec
07/05/2016
Which of these would you choose for your SIS?
Proline launch conference 2016: On the evolution of Functional Safety
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
Slide 24 Daniel Maglione, Flowtec
07/05/2016
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 25 Daniel Maglione, Endress+Hauser Flowtec
07/05/2016
Proline launch conference 2016: On the evolution of Functional Safety
How do the “old” and “new” PFD values compare?
SIL 2
SIL 3
SIL 1 Typical SIL capable flowmeters on the market, e.g. Promass 83
Promass 200 73 FIT
160 FIT
Heartbeat continuously diagnoses whether failures have occurred. The scope of the diagnostics in the SIL mode corresponds to the SFF.
PTC for Heartbeat Verification = 0%
Slide 26 Daniel Maglione, Flowtec
07/05/2016
Proline launch conference 2016: On the evolution of Functional Safety
More safety! Less effort! More flexibility!
SIL 2
SIL 3
SIL 1 Promass 200 – 73 FIT
Typical SIL capable flowmeters – 160 FIT
• Dedicated instrument design to achieve highest safety requirements
• Increased safety by best-in-class diagnostic coverage • Enabling prolonged proof-test intervals
Slide 27 Daniel Maglione, Flowtec
07/05/2016
Proline launch conference 2016: On the evolution of Functional Safety
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!
Slide 28 Daniel Maglione, Flowtec
07/05/2016
E.g. proof test procedure of Liquiphant
• Liquiphant directly integrated in PLC
• Proof test via proof test button at the Liquiphant
• With pushing the proof test button a test routine (start up) is generated
• Signal processing and signal output is tested
• In addition to the internal permanent test, the output signal is triggered (demand 6 or 9mA) and a test of the connected devices is initialized
Safety PLC
Tuning forks – THE device for overfill prevention
Slide 29 P. Borggreve
FailSafe - 4-20 mA FEL85
uncovered covered Sensor- fault
3,6 mA
LIVE-Signal
13,5 mA 6 mA
Heartbeat Technology
07/05/2016
Proof Test Verification
Shell Tech Meeting 2015 - Endress+Hauser Maulburg
Heartbeat Technology
• Highest safety and availability SFF (TTC) > 99%
• Reduction of unplanned downtime
• Reduction of total cost of ownership
• Extended proof test interval up to 12 years
• Easy proof test via push button without process interruption with clear indication passed/ failed
• Simplified testing of the complete system including the following devices within the safety loop
• Standardized documentation (proof test protocol)
Slide 30 MTF
Valve strokes
07/05/2016
Easy proof test – savings while proof test
Micropilot FMR5x – Next Level Instrumentation
Slide 31 MTF/moe
Benefit:
• Time to fill the tank to max level or to remove the device and test it (no device self check available) 80 - 480 min/a
• SIL proof test with device self check every 3rd year (app. 30 min) 10min/a
• Downtime savings for the plant 70 – 470 min/a
1h production ~5000$ depending on product >5.800 – 39.000$/a
Cost
Savings > 39.000$ Downtime
07/05/2016
• 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
Heartbeat Verification
Proline launch conference 2016: On the evolution of Functional Safety
Verification report
in accordance with IEC 61511-1, Section 16.3.3
Slide 32 Daniel Maglione, Flowtec
07/05/2016
Built-in vs External Verification
Welcome to Heartbeat Technology!
Heartbeat Verification Fieldcheck • Built-in
• Embedded test functionality
• App. 10 minutes
• Total test coverage* TTC > 98% acc. to IEC 61508
• External
• Simulation and sensor checking
• 30 to 60 minutes
• Proof-test coverage 90% or better
*Cumulative rating of safe failure across entire device electronics
Slide 33 PC Flowtec Marketing
Benefits of Built-in verification • Save time • Safety - less man hour in field • Reliable - Higher PTC • Documentation
07/05/2016
Heartbeat Verification and Monitoring on demand
Heartbeat Technology Outlook
Pass / Fail report generated by Heartbeat Technology
• The verification can be performed without dismounting the device which saves costs and reduces the plant downtime.
Heartbeat Technology
Slide 34 D. Haag
07/05/2016
Heartbeat Monitoring
Benefits of Endress+Hauser’s Level and Flow 2-wire portfolio featuring Heartbeat Technology
Slide 35 Daniel Maglione PCF & Stefan Jäger PCM
07/05/2016
Process monitoring of your process
Micropilot FMR5x – Next Level Instrumentation
Animation of foam measurement
(explained on a Micropilot)
Slide 36 RV
07/05/2016
Process monitoring – the “Heart beat” of your process
Micropilot FMR5x – Next Level Instrumentation
Build up on an antenna
(explained on a Micropilot)
Slide 37 RV
07/05/2016
Self-Monitoring
Tuning forks – THE device for overfill prevention
• Continuous monitoring of vibration frequency • Safe alarm function
sensor
alarm 0,4 s delayed
400 fa-15%
fa fa+ 6,5%
1500 f [Hz]
25 mm
1 inch
0
0
Immersion depth
corrosion
alarm 60 s delayed
sensor
Alarm 0,4 s delayed
normal operation
fa-15% switch point approx. 850 Hz
A
L
A
R
M
A
L
A
R
M
fa oscillation frequency in air
approx. 1 kHz
Slide 38 P. Borggreve
07/05/2016
Proof - Safe response to Corrosion & Erosion
Tuning forks – THE device for overfill prevention
Slide 39 P. Borggreve
No problem for tuning forks reliable switch point
07/05/2016
Heartbeat Monitoring: Corrosion
Corrosion may occur in manifold forms, so condition monitoring requires a variety of
parameters, particularly here.
Base values
Gradual, steady drift
The density measurement can be tracked in addition, if the fluid is unchanged.
Slide 40
Check
• Tube damping
• Signal asymmetry
• Resonance frequency
Coriolis Measuring Tubes
07/05/2016
Heartbeat Technology overview
Proline launch conference 2016: On the evolution of Functional Safety
Monitoring Verification Diagnostics
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 41 Daniel Maglione, Flowtec
07/05/2016
Heartbeat addresses your most serious challenges
Availability Quality Safety
Welcome to Heartbeat Technology!
Slide 42 PC Flowtec Marketing
Minimized cost for quality assurance and
documentation
Best-in-class safety and reliability
Simplified handling, flexible instrument access
RELIABILITY
EXPENDITURE
07/05/2016
Products Solutions Services
Thank you very much for your attention
Products Solutions Services
Safety in the process industry
Simply reliable
Table of content
•Safety by design
•Safety by manufacturing
•Safety during operation
Safety in the process industry
Products Solutions Services
Safety by Design
A lifetime commitment
Safety by Design – A lifetime commitment
• Endress+Hauser design standards
• Material selection
• Design simulations using Finite Element Methods
• Mechanical design stress testing
• Welding procedure specifications
• Sealing concepts
• Inherently safer designs
Safety in the process industry
Endress+Hauser design standards
• Design and testing experience built
on generations of product history
within Endress+Hauser, customers
and industry/academic
organizations
• Costly and unproductive
complexity is avoided by
standardized development across
al Endress+Hauser operations
• These standards helps
Endress+Hauser reduce risk in the
design, manufacturing and
documentation of products. In
return helping us reduce risks to
our customers
Safety in the process industry
Diagnostic according to NAMUR NE 107
Proline Prowirl 200 – Service aspects
Slide 6 MTV
Picture of wet steam through a sight glass taken on the Alice steam rig
80% steam quality
Material Selection
• Metals
• The selection of the correct type and form of metals used within an
instrument is built on years of experience and testing
• Plastics/elastomers
• A wide variety of non metallic polymer materials are available for seals,
containment, insulation, etc
• Glass/ ceramics
• Non-metallic materials such as glasses, graphites, ceramics are typically
selected for seals, insulation, etc. for demanding service especially under
higher temperatures and pressures
• Heterogeneous assemblies
• Assemblies with combinations of materials can have complex interactions
that must be suitable for the design service
• Understanding how the combination of forms and compositions will
behave is critical to achieve a low risk service design
Safety in the process industry
Safety in the process industry
Design simulations in development phase Endress+Hauser uses the latest design Finite Element Analysis (FEA)
tools to simulate real-world effects (i.e. fatigue, failure) on designs
from mechanical forces, heat, vibration, fluid flow and other physical
stresses to reduce risk.
Difference in mechanical stress on socket of Liquiphant fork of SS316 and Duplex Steel
Thermowell design calculation
Safety in the process industry
Stress testing
• Vibration testing
• Testing of prototype components or final products to ensure the final design will
provide expected resistance
• Amplitude and frequencies (g forces) are varies in X,Y and Z directions
• Shock testing
• Subjecting components or final products to abrupt forces or strikes to test integrity
as specified
• Fatigue testing
• Some components in a design subjected to mechanical movement over time may
develop weakness leading to failure
• Repetitive flexing or mechanical movement may be conducted over a period of
time to ensure the right material for the design is used
• Burst testing
• Testing is conducted on a component or final product to pinpoint the kevel a which
function or containment is lost
Safety in the process industry
Safety in the process industry
Robust design - StrongSens
• Robust PT100 thin film sensor with outstanding vibration resistance (60g) for temperature up to 500°C
• Reproducible, high quality via automated production
Unique sensor technology for demanding applications
Longest life time with optimized operation safety
Proline Prowirl – Reliable measurement under extreme conditions
Safety in the process industry
Welding procedure specifications
• Welding procedure specifications (WPQR/ WPS) are managed
according to required standards
• Clear and transparent guidelines prevent defective work in
manufacturing and customer documentation.
Safety in the process industry
Sealing concepts
• Instruments by their nature are often installed in hazardous areas,
inserted into extreme process pressures, temperatures and exposed
to all types of materials
• An instrument needs to be robust enough to avoid a release of
process material or needs to be predictable in how it releases process
material so risk is managed
Safety in the process industry
Liquiphant Failsafe
Safety in the process industry
Products Solutions Services
Safety by Production
Safety by Production –A lifetime commitment
• Manufacturing quality assurance
• Material traceability
• Positive Material Identification (PMI) testing
• Radiographic (RT) testing
• Dye penetrant (DPI) testing
• Welding Procedure Qualification Reports
• Hydrostatic pressure testing
• Helium leakage testing
Safety in the process industry
Manufacturing quality assurance
• The quality assurance systems at Endress+Hauser are based on ISO
defined criteria and regularly audited by external agencies
• ISO 9001 Quality Management System
• ISO 14001 Environmental Management System
• OHSAS 18001 Occupational Health and Safety Management System
• All Endress+Hauser companies take product quality and customer
safety very seriously and continuously challenge their internal quality
systems
• Each employee in our organization shares the responsibility for
consistently producing the products expected by our customers and
maintaining a safe production environment
Safety in the process industry
Material traceability
• Maintaining absolute material identification, inventory and
traceability from incoming stock to finished delivered product
• Material traceability is required by process plant engineering and
construction operations to ensure predictable containment integrity
Safety in the process industry
Positive Material Identification (PMI)
• Endress+Hauser uses PMI testing as a non-destructive method which
does not affect the material properties. It is not a substitute for a
traceability certificate
• PMI testing is performed by emitting X-rays on the material to be
tested which then responds by sending out XRF (X-ray fluorescence)
signals of varying energy and intensity depending on its chemical
composition. The XRF signals are then recorded by an XRF analyzer
Safety in the process industry
Radiographic (RT) testing
• Endress+Hauser uses industrial radiography ray
testing to inspect materials for hidden flaws to
reduce risk
• RT testing reveals material defects on metallic
materials. It is especially well suited for welding
seam analysis since even very small defects can
be identified.
• Non-destructive as it does not affect the material
properties or leave any marks on the measured
surface
Safety in the process industry
Dye penetration (DPI) testing
• Dye penetrant inspection (DPI), also called liquid penetrant
inspection (LPI) or penetrant testing (PT), is used by Endress+Hauser
to locate surface breaking defects in all non-porous materials
• DPI is used to detect casting, forging and welding surface defects such
as hairline cracks, surface porosity, leak path and fatigue cracks on
components
Safety in the process industry
Welding procedure qualification
• Welding seams on Endress+Hauser products are produced by
automatic welding machines according to instrument specific
Welding Procedure Qualification Record/ Welding Procedure
Specification (WPQR/WPS) are controlled by approved welding
personnel
• Frequent inspection of both welding machines and the resulting
welding seams are conducted to maintain the highest quality
demands and regulatory requirements.
Safety in the process industry
Hydrostatic pressure testing
• Hydrostatic testing is a safer way to verify the integrity of a
manufactured instrumentation component that is designed for
pressure service
Safety in the process industry
Helium leakage testing
• Leak testing is a non-destructive test that can be applied to a
fabricated component to verify it is leak proof
Safety in the process industry
Test Center – Passion for quality and safety
Safety in the process industry
Products Solutions Services
Safety during Operations
Levelflex – FMP54 – Heavy duty under harsh conditions
Safety in the process industry
Cerabar S/Deltabar S – Secondary Containment
Safety in the process industry
Sealing concept of Proline Prowirl Vortex Sensor
Safety in the process industry
Proline Promass Secondary Containment
• Serves as additional safety measure if a fluid is extremely
corrosive/abrasive.
• In case of a measuring tube failure the secondary containment can
hold the fluid back avoiding dangerous spills.
Safety in the process industry
Secondary containment
Measuring tube Rigid carrier tube
Filled with Nitrogen Second line of defense
Proline Promass inherently safe sensor design
Purge connections
Safety in the process industry
Unmatched Safety Concept: 3 Sealing Barriers
Safety in the process industry
Standard flanged
connection with
thermowell
Safety chamber with
removable head
Failure 1 (a broken
point on the
thermowell)
Second barrier: the
process stops here
Safe operation also in
fault condition no shut
down necessary
Third barrier: the
process stops here
Safe operation also in
fault condition no
immediate shut down
necessary
Failure 2 (a broken
point between the
flange and the tube’s
welding)
Plant startup
Thermowell = First
barrier
Safety in the process industry
Something to think about…
• Analysis of 34 incidents, based on 56 causes identified
Source: HSE - UK
Mechanical integrity planning
• Endress+Hauser provide tools to reduce risk of incorrect mechanical
components specification and selection for specific service
• Visit our website: www.my.endress.com
Safety in the process industry
APPLICATOR DEMO
Safety in the process industry
Applicator: Corrosion warning and database
Make a proper choice right from the beginning.
Safety in the process industry
Robust materials
Promass O – SuperDuplex Beating stress corrosion cracking
Promass H – Tantalum Resistance against concentrated acids
Ceraphire – Corrosion and abrasion resistant; even applicable in vacuum
Inherently “Safer” Design
Ultrasonic Clamp On – Non intrusive measurement
• Process pipe integrity is unaffected by drilling, welding etc.
• Leak potential is removed from the flow meter installation
• No personal exposed to the process (hazardous material)
Safety in the process industry
Real life application challenges
Even the most powerful selection tool has limits:
Therefore discuss openly the challenges in your application with our
sales engineers.
Safety in the process industry
Products Solutions Services
Safety by choice – not by chance
Products Solutions Services
Thank you very much for your attention