process safety seminar - endress+hauser · •storage of device parameters ... 05.46, the vapour...
TRANSCRIPT
02/20/2015
Why do we need to go to the next level….?
RV Slide 2
So your plant becomes safer. So you have better process control, leading to improved productivity and quality. So you can predict maintenance and service activities pro-active in stead of in a constant crisis mode.
How do you know that what an instrument measures is right and why is that important?
02/20/2015
Heartbeat Technology™ - elements
Heartbeat Technology
Heartbeat Verification
Heartbeat Diagnostics
Heartbeat Monitoring
• ------------------ • ------------------ • ------------------ • ------------------ • ------------------
Pass / Fail
Heartbeat Technology™
Slide 3 Rob Vermeulen
02/20/2015
Heartbeat Technology
Continuous output of data influenced by process
Continuous self-diagnostic of Level, Flow and Pressure instruments
On demand confirmation of instrument functionality
Heartbeat Technology™ - in operation
Heartbeat Verification
Heartbeat Diagnostics
Heartbeat Monitoring
• ------------------ • ------------------ • ------------------ • ------------------ • ------------------
Pass / Fail
Slide 4 RV
02/20/2015
Onboard diagnostics – running in the background
Micropilot FMR5x – Next Level Instrumentation
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 5 RV
02/20/2015
Measurement signal Verification – Multi Echo Tracking
Micropilot FMR5x – Next Level Instrumentation
Animation to describe the Multi-Echo Tracking
(explained on a Micropilot)
Start by click the animation
Slide 6 RV
02/20/2015
Process Monitoring
Micropilot FMR5x – Next Level Instrumentation
Process Monitoring…….
• Distance • Terminal voltage • Electronic temperature
• Relative echo amplitude (Signal/noise ratio)
- Build up on antenna - Foam level - Product identification (oil or water etc)
Slide 7 RV
We give you more than a mere measured value.…
02/20/2015
Process monitoring – the “Heart beat” of your process
Micropilot FMR5x – Next Level Instrumentation
Animation of foam measurement
(explained on a Micropilot)
Start by click the animation
Slide 8 RV
02/20/2015
Process monitoring – the “Heart beat” of your process
Micropilot FMR5x – Next Level Instrumentation
Build up on an antenna
(explained on a Micropilot)
Start by click the animation
Slide 9 RV
02/20/2015
Do I need “software” to monitor Heart beat?
Micropilot FMR5x – Next Level Instrumentation
Plastic Alu 316L
4-20mA 4-20mA
Housing
4-20mA PFS
4-20mA DC
4-20mA AC
Approval
Electronics
ATEX
2-wire 4-wire
HistoROM +
mechanical buttons or optical buttons for operation
from outside
Display
Remote Display FHX50
4-20mA –
FMR50 FMR51 FMR56 FMR57 FMR54 FMR52 FMR53 + 100mm horn
up to 250°C or 450°C up to 400°C
basic solid solid basic liquid liquid hygienic/corrosion resistant
insulated HT/HP
+ 100mm horn + planar
316L
plastic
Slide 10 Rob Vermeulen
02/20/2015
….. But you can. DTM start page with clear instrument health status
Micropilot FMR5x – Next Level Instrumentation
Example for Micropilot
Health status
Health status
F/C/S/M Clear diagnostic message +
Remedy information
Slide 11 Rob Vermeulen
02/20/2015
Micropilot FMR5x SAFE – PRECISE – EFFICIENT
Micropilot FMR5x – Next Level Instrumentation
EFFICIENT The Micropilot FMR5x offers a so called HistoROM data management concept function to make maintenance, diagnosis and setup of the device as easy and fast as possible
Slide 12 Rob Vermeulen
02/20/2015
HistoROM
Micropilot FMR5x – Next Level Instrumentation
The HistoROM is fixed in the housing (can not be lost or “forgotten”)
• Functions HistoROM: • Storage of device parameters
• Storage of event log book (basic: 20 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 a screw driver is necessary
• History information for diagnostic purposes
• Safety for configuration data without a SW–tooling, time saving full restore and backup
• Time saving setup of tank farms with import of settings from device to device
Slide 13 Rob Vermeulen
02/20/2015
Animation HistoROM
Micropilot FMR5x – Next Level Instrumentation
Start by click the animation
Slide 14 Rob Vermeulen
02/20/2015
HistoROM
Micropilot FMR5x – Next Level Instrumentation
Electronic change during night shift
The HistoROM is fixed in the housing (can not be lost or “forgotten”)
Example HistoROM functionality
Slide 15 Rob Vermeulen
02/20/2015
Extended HistoROM
• Coming free of charge with
• Levelflex HART (SW 1.02.00)
• PA & FF follow later this year
• Storage of
• Event recorder according to Endress+Hauser standard
• 100 events
• Recording of trends (FIFO memory)
• Up to 4 independent parameters (e.g level, Temp, S/N, terminal voltage etc)
• Max. 500 values / 1 parameter
• Or 250 values (with 2 parameters), …, 125 values (4)
• Storage of reference curve
• Comparison to start up / commissioning conditions for maintenance
The HistoROM is fixed in the housing (can not be lost or “forgotten”)
Slide 16 MTF/STJ
Micropilot FMR5x – Next Level Instrumentation
02/20/2015
Extended HistoROM – Event List – up 100 events
Slide 17 MTF/STJ
Micropilot FMR5x – Next Level Instrumentation
02/20/2015
Extended HistoROM - Trend
• Visualization of up to 4 trend values • Visualization of events in correlation with trend values
Slide 18 MTF/STJ
Micropilot FMR5x – Next Level Instrumentation
02/20/2015
Extended HistoROM - Statistics
• Statistical information about recorded values (application related)
Slide 19 MTF/STJ
Micropilot FMR5x – Next Level Instrumentation
02/20/2015
Diagnosis: Reference curve
Reference curve: The reference curve shows a previous state of the envelope curve! It can be recorded manually under Expert>>Diagnostics>>Envelope Diagnostics. Reading the envelope curve is possible with the read reference curve button:
Raw envelope curve: Envelope curve signal without any filter (e.g. smoothing, MAM, low pass,…) has to be separately activated via the read settings:
Button to read reference curve
Slide 20 MTF/STJ
Micropilot FMR5x – Next Level Instrumentation
02/20/2015
Products Solutions Services
Proof testing…. Necessary, Safe and Practical.
Next Level Instrumentation
Slide 21
02/20/2015
FMR5x series
And now something completely different…..
RV Slide 22
• Please stand up and introduce yourself to the person on the right of
you.
• Small introduction of how a Dutch guy sees Canada.
02/20/2015
How does a Dutch guy see Canada and it’s inhabitants?
RV Slide 23
Practical
Sporty people modest
Multi culti
Have humor
Snow
02/20/2015
Products Solutions Services
Proof testing…. Necessary, Safe and Practical.
Next Level Instrumentation
Slide 24
02/20/2015 Slide 25 / 49
Incidents Preceding Improved Safety Standards
Pernis Oil Refinery, Holland
Jan 20, 1968 (2 dead, 85 injured)
Flixborough, UK
Jun 1, 1974 (28 dead, hundreds injured)
Seveso, Italy
Jul 10, 1976 (700 injured)
Bhopal, India
Dec 2, 1984 (2,500 dead, 100,000 injured)
Piper Alpha, UK (North Sea)
Jul 6, 1988 (165 dead, 61 injured)
Still happening…….
02/20/2015 Slide 26 / 49
Still happening…….
Firefighters fight flames at the BP plant in Texas City after
the July 28, 2005 explosion. (15 dead & 170 injured)
Still happening…….
02/20/2015
Setting The Pace For Tank Safety!
The Buncefield fire - Sunday 11 December 2005
Investigation by the HSE (Health & Safety Executive) • 10 December 2005: at around 19.00, Tank 912 started
receiving unleaded motor fuel from at about 550 m3/hour
• 11 December 2005: From approximately 03.00, the level gauge was stuck at 2/3 full
• Filling continued with around 550 m3/hour
• At 05.20 tank starts overflowing
• Evidence shows that the protection system did not operate
• CCTV footage shows vapour starting to flow and at 05.46, the vapour cloud was 2 m deep and flowing out of the bund in all directions
• By 05.50, the vapour cloud had started flowing off site
Source Buncefield reports
02/20/2015 Slide 28 / 49
The Buncefield fire - Sunday 11 December 2005
Investigation by the HSE (Health & Safety Executive)
• At 06.01, the first explosion occurred
• Fire, engulfs over 20 large fuel storage tanks • 43 people injured in the incident • Amazingly no fatalities • Several Buildings damaged • The fire burned for 3 days…
Source Buncefield reports
02/20/2015
So how can help prevent this in future? Overfill Prevention Cabinets according to API 2350
02/20/2015 Slide 30 / 49
WHG
RMA42
2
RMA42
2
FTL325P SIL 2
SIL 2/3
Tankvision Scanner
IEC 61511 SIS loop
Limit Hi
Display
Fill Limit
Display
Limit HiHi
Display
Level, Temperature,
Volume, Pressure,
Alarms, …
• Ethernet TCP
Operator Limit
A
Logic Solver
OPC
Level limit
• PFM
• DO
• Namur
Level
• 4-20mA
Level Limit
• DO
SIL 2 SIL 2
Level Limit
• DO
Level, Temperature,
Pressure …
• Modbus
• V1
• others
Level,…
• 4-20mA
Limit B
• DO
Level
• 4-20mA
Limit A
• DO
Level Limit
• DO
PLC
Operator Limit
n
Inventory System
…
Other values required
For Operator
• Ethernet OPC
SIS Logic
Limit HiHi
• DO
•Ethernet OPC
Overfill P
reventio
n
Tan
k In
vento
ry M
easu
rem
ent
HMI
Separate overfill prevention from the tank gauging system…
API 2350
Simple Rules Still Apply
02/20/2015 Slide 31 / 49
Proof Testing for bulk liquid storage tanks
Fig. a. storage tank with conical roof Fig. b. storage tank with external floating roof
Fig. c. storage tank with internal floating roof
Fig. d. storage tank with (external) floating roof and (retrofit) dome roof
Possibilities are determined by tank constructions
Simple Rules Still Apply
02/20/2015 Slide 32 / 49
Fixed Roof – SAFE LAHH Solutions
Liquiphant – Vibronics, Tuning Fork
Measurement of aggregation phase by fluid density, Gas versus
Liquid
Levelflex – Guided Wave Radar, Time Domain Reflectometry
Measurement of true level using dielectric reflection at phase
change
02/20/2015 Volker Schulz Slide 33 / 49
Proof testing
• Push button activated
test generator (annual)
• High proof test
coverage
• By expert inspection
• Proof test coverage
depends on inspection
depth
Mounting
Functional Safety
• IEC 61508 design • Proven in use • Suitable for SIL 2 / 3 (3 when
used in homogeneous redundancy)
• Switching in remote switch unit • Discrete output (relays)
• Proven in use • Suitable for SIL 2 • Internal redundancy (EOP) • Analogue output (4-20 mA) • Comparison potential to TG system (deviation) • Switching in safety system or RMA422
Fixed roof solutions
Liquiphant
Guided Wave Radar (TDR)
Side Top
Top adjustable
Top
02/20/2015 Slide 34 / 49
Liquid Bulk Storage Independent High Level Alarms – Best technology Available
Liquiphant is always the first solution.
Internal Floating Roofs and External Decks do require stilling wells or side mounted nozzles to be installed.
02/20/2015
Volker Schulz Slide 35 / 49
Guided radar as over spill protection
Levelflex as SIL 2 overspill protection on Fixed roof tanks and LPG bullets
02/20/2015 Slide 36 / 49
Floating Roof – SAFE LAHH Solutions (Liquiphant – Stilling well mounting is always preferred)
Micropilot – Free Field Radar, Time of Flight
Measurement of roof level using dielectric reflection at phase
change
Liquicap – Capacitance type contact switching
Measurement of dielectric impedance change by roof contact
02/20/2015
Damaged deck
• May lead to lost and
deflected echo
depending on deck
position
• Fails Safe
• Switch level may raise
depending on deck
position
• May fail when deck
gets over flooded
Lost deck
• May lead to some
switch point deviation
(up to 100 mm)
• No failure
• May lead to severe
switch point deviation
• Fails dangerous
• May become safe
when weight is
modified
Snow cover
• May lead to lost echo
• Fails Safe
• Availability increased
using new Advanced
Dynamics design
• Top of snow detected
as raised level
• No Failure
(external) floating roof failure scenarios
Free space Radar
Capacitance type
02/20/2015 Volker Schulz
Floating Roof Tanks Independent High Level Alarms / Radar – Proof Testing external
External Swivel plate for functional
proof testing
Combined Swivel plate for functional
proof testing