heartbeat technologytm - my.endress.com...heartbeat technologytm the pulse of your measurements...

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

PDF



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



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


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)


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?


λDU SFF PFD PFDavg

FIT

How to understand and use these data?


07/05/2016

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


SFF [%] Safe Failure Fraction

Safe & Detectable

Safe & Undetectable

Dangerous & Detectable

Dangerous & Undetectable


07/05/2016

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


07/05/2016

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


07/05/2016


How does the PFD chart relate to the SIL level?

SIL 2

SIL 3

SIL 1


07/05/2016


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!


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


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


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


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

In a factory calibration rig…


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


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


07/05/2016

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


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


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%


07/05/2016


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


07/05/2016


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!


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



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


• 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


Verification report

in accordance with IEC 61511-1, Section 16.3.3


07/05/2016

Built-in vs External Verification


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


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.


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


Animation of foam measurement

(explained on a Micropilot)

Slide 36 RV

07/05/2016

Process monitoring – the “Heart beat” of your process


Build up on an antenna

(explained on a Micropilot)

Slide 37 RV

07/05/2016

Self-Monitoring


• 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


07/05/2016

Proof - Safe response to Corrosion & Erosion



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


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


07/05/2016

Heartbeat addresses your most serious challenges

Availability Quality Safety



Minimized cost for quality assurance and

documentation

Best-in-class safety and reliability

Simplified handling, flexible instrument access

RELIABILITY

EXPENDITURE

07/05/2016


Thank you very much for your attention


Safety in the process industry

Simply reliable

Table of content

•Safety by design

•Safety by manufacturing

•Safety during operation



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


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


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



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


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



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


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.


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


Liquiphant Failsafe



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


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


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


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


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


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


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.


Hydrostatic pressure testing

• Hydrostatic testing is a safer way to verify the integrity of a

manufactured instrumentation component that is designed for

pressure service


Helium leakage testing

• Leak testing is a non-destructive test that can be applied to a

fabricated component to verify it is leak proof


Test Center – Passion for quality and safety



Safety during Operations

Levelflex – FMP54 – Heavy duty under harsh conditions


Cerabar S/Deltabar S – Secondary Containment


Sealing concept of Proline Prowirl Vortex Sensor


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.


Secondary containment

Measuring tube Rigid carrier tube

Filled with Nitrogen Second line of defense

Proline Promass inherently safe sensor design

Purge connections


Unmatched Safety Concept: 3 Sealing Barriers


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


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


APPLICATOR DEMO

http://www.my.endress.com/


Applicator: Corrosion warning and database

Make a proper choice right from the beginning.


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)


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 by choice – not by chance


Thank you very much for your attention

heartbeat technologytm - my.endress.com...heartbeat technologytm the pulse of your measurements...

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