Syllabus studiedag 23 april 2015 Ingenieurshuis, Antwerpen www.ie-net.be/SIL

3. Expertgroep Meet- en Regeltechniek
De expertgroep Meet- en Regeltechniek wil volgende mensen bereiken:
 afgevaardigden uit leveranciers-middens
 afgevaardigden uit bedrijven, studie- en engineeringsbureaus
 onderwijzers uit secundair en hoger onderwijs
Met volgende activiteiten
 avond voordrachten: aanwending van nieuwe apparatuur, methode of technologie, in
samenwerking met firma's.
 studiedagen: themagericht en vergezeld van demonstraties of tentoonstelling, in
samenwerking met fabrikanten.
 themagerichte cursussen
 discussievergaderingen: voor eigen vorming binnen de studiegroep, met medewerking
van specialisten.
Wij zijn steeds tot uw dienst!
U kan een beroep op ons doen om u te begeleiden in typische meet- en regelproblemen.
Daarenboven bent u steeds welkom
De expertgroep Meet- en Regeltechniek vergadert elke 1ste dinsdag van de maand om 20 uur,
Ingenieurshuis Antwerpen, Desguinlei 214, 2018 Antwerpen
(Behalve in juli en augustus)
Voorzitter Secretaris
Jos Serneels Ing. Patrick Viskens MSc
Deze studiedag werd mede gesponsord door

5. Proces
risicoanalyse
MAATREGELEN
ontwerp
controlesystemen
procedures
instrumentele kringen
menselijke interventie
mechanische toestellen
schadebeperkende maatregelen

6. Design and Engineering
of
SIS
Installation,
Commissioning
and Validation
Operation & Maintenance
Modification
Decommissioning
Safety Requirements
Specification
for the SIS
3
4
5
6
7
8
Verification
Safetylifecycle
structureandplanning
Managementof
functionalsafetyandfunctionalsafetyassessmentandauditing
Development of other
Design and
means of
Risk Reduction
Allocation of Safety
Protection Layers
Functions to2
Hazard & Risk
Analysis1

8. Poper max = 3 barg
–
–

9. ERNST (gevolg) WAARSCHIJNLIJKHEID (kans)
A B C D E F
Ernst
klasse
Mens
Financiële
gevolgen
Milieu Reputatie
Waarschijnli
jkheid
kleiner dan
eens per
10.000 jaar
10-5 W < 10-
4
Waarschijnlij
kheid kleiner
dan eens per
1000 jaar
10-4 W < 10-3
Waarschijnl
ijkheid
kleiner dan
eens per
100 jaar
10-3 W <
10-2
Waarschijnlij
kheid kleiner
dan eens
per 10 jaar
10-2 W < 10-1
Waarschijnlij
kheid kleiner
dan eens
per jaar
10-1 W < 10-0
Waarschijnlijk
heid gelijk of
groter dan
eens per jaar
W 10-0
1 EHBO
Onwel < 10 k€
Geringe emissie of
schade binnen
terreingrenzen
Klachten
van
omwonend
en
1xper100.000jaar
1xper10.000jaar
1xper1000jaar
1xper100jaar
1xper10jaar
1xperjaar
2
Licht letsel.
Tijdelijk
aangepast
werk.
< 100 k€
Lichte overschrijding
toelaatbare emissie.
Geen blijvende schade
buiten terreingrenzen.
Lokale
media/
klachten
3
Ernstig
letsel met
werkverzuim
< 500k€
Overschrijding
vergunning. Effect
buiten terreingrenzen.
Regionale
verslaggev
ing/
klachten
4
Zeer ernstig
blijvend
letsel of
dode
< 10 MM€
Ernstige
overschrijding.
Emissie met schade
aan milieu. Correctieve
maatregelen buiten
poort noodzakelijk.
Nationale
verslaggev
ing/
klachten
5 Meerdere
doden > 10 MM€
Ernstige ecologische
effecten. Economische
schade.
Internation
ale
verslaggev
ing
ERNST (gevolg) WAARSCHIJNLIJKHEID (kans)
A B C D E F
Ernst
klasse
Mens
Financiële
gevolgen
Milieu Reputatie
Waarschijnli
jkheid
kleiner dan
eens per
10.000 jaar
10-5 W < 10-
4
Waarschijnlij
kheid kleiner
dan eens per
1000 jaar
10-4 W < 10-3
Waarschijnl
ijkheid
kleiner dan
eens per
100 jaar
10-3 W <
10-2
Waarschijnlij
kheid kleiner
dan eens
per 10 jaar
10-2 W < 10-1
Waarschijnlij
kheid kleiner
dan eens
per jaar
10-1 W < 10-0
Waarschijnlijk
heid gelijk of
groter dan
eens per jaar
W 10-0
1 EHBO
Onwel < 10 k€
Geringe emissie of
schade binnen
terreingrenzen
Klachten
van
omwonend
en
1xper100.000jaar
1xper10.000jaar
1xper1000jaar
1xper100jaar
1xper10jaar
1xperjaar
2
Licht letsel.
Tijdelijk
aangepast
werk.
< 100 k€
Lichte overschrijding
toelaatbare emissie.
Geen blijvende schade
buiten terreingrenzen.
Lokale
media/
klachten
3
Ernstig
letsel met
werkverzuim
< 500k€
Overschrijding
vergunning. Effect
buiten terreingrenzen.
Regionale
verslaggev
ing/
klachten
4
Zeer ernstig
blijvend
letsel of
dode
< 10 MM€
Ernstige
overschrijding.
Emissie met schade
aan milieu. Correctieve
maatregelen buiten
poort noodzakelijk.
Nationale
verslaggev
ing/
klachten
5 Meerdere
doden > 10 MM€
Ernstige ecologische
effecten. Economische
schade.
Internation
ale
verslaggev
ing

10. Frequentie van
initiële oorzaak
BESCHERMINGSLAGEN Eindfrequentie gevolg
=
richtfrequentie
OORZAAK GEVOLGBESCHERMINGSLAGEN
Regelkring
faalt Vrijzetting
Instrumentele
beveiliging in
veiligheidsPLC
veiligheidsklep
10
100
1
10 jaar
1
100 jaar
1
10.000 jaar
Hoe groter het gevolg, hoe kleiner de frequentie waarmee men dit gevolg
kan accepteren. Dus hoe meer risicoreductie er nodig is.

11. Frequenties
voor initiële
oorzaken
Calibratie
richtfrequenties
gevolgen
EISEN
beschermingslagen
LOPA

12. LIC
LT
LIC
LT

13. Regeling
faalt
Tank scheurt open
met grote vrijzetting
Instrumentele
beveiliging
Veiligheidsklep
100 (SIL1)
1
10 jaar
1
100 jaar
1
100.000 jaar
100
Regeling
faalt
Veiligheidsklep blaast
vloeibare LPG af
Instrumentele
beveiliging
1000 (SIL3)
1
10 jaar
1
10.000 jaar
•
•
•

14. •
•

15. –
–
–
–

25. Process Automation Solutions NV
An ATS Company
Doc. Vers.: 10Date
Safety Requirement Specifications:
Do’s and Dont’s
Process Safety Event VIK
© Process Automation Solutions NV – An ATS company
Inleiding
Lifecycle IEC61511
Doc. Vers.: 4

26. © Process Automation Solutions NV – An ATS company
Inleiding
Waarom Specificatie
Doc. Vers.: 4
The safest risk is the one you didn’t take.
Source: Health & Safety Executive HSE - UK)
© Process Automation Solutions NV – An ATS company
First things first
Slechte risicobepaling en/of weging
Garbage in -> garbage out
Respecteer de volgorde van Layers Of Protection.
Terug naar het ontwerp?
Doc. Vers.: 4

27. © Process Automation Solutions NV – An ATS company
First things first
Do’s opgave
Eén per Safety Integrated Function
Verantwoordelijkheden
Opgave
Unieke identificatienummer van de beveiligingskring
Wat kan er gebeuren
Wat zijn de oorzaken
Wat zijn de gevolgen
Wat ga ik eraan doen
Wat zijn de normale omstandigheden van het proces
Wat zijn de uiterste limieten van het proces
Hoe zorgt deze schakeling ervoor dat ik mijn veilige toestand bereik.
Wat is het gevolg van het schakelen van deze functie (niet alleen de gewenste)
Hoe snel moet de functie werken.
Te behalen veiligheidsniveau.
….
Doc. Vers.: 4
© Process Automation Solutions NV – An ATS company
First things first
Do’s technische uitwerking
De eisen aan welke de technische oplossing zou moeten voldoen.
Voting
Trippunt.
MTTR
Hoe ga ik deze functies visualiseren.
Wat doe ik bij spanningsuitval.
Zijn er relevante weersinvloeden en welke maatregels tref ik hier tegen.
Zijn er relevante proces invloeden en welke maatregels tref ik hier tegen.
Hoe snel moet de technische oplossing zijn ( PST!)
Welke diagnose is er vereist.
Welke lekklasse is er noodzakelijk
….
Doc. Vers.: 4

28. © Process Automation Solutions NV – An ATS company
First things first
Don’ts
Merk, type, range van de het toestel dat je voorzien hebt.
Welke range hoort dan wel in een SRS?
Eerst specifiëren dan bestellen.
Maatregel is (deels) de oorzaak
Digitaliseren van de as-buildt toestand.
Specificatie realisatie.
Negeren randeffecten
Blind volgen “lijstjes”
Doc. Vers.: 4
© Process Automation Solutions NV – An ATS company
First things first
Aandachtspunten
Prooftesting
Bypassing (MOS)
Availability
Worst case
Algemene kennis meet/regel
CRC/SIT/007-N
IEC61508/11
Doc. Vers.: 4

29. © Process Automation Solutions NV – An ATS company
Voorbeelden
Wat kan er gebeuren
Wat zijn de oorzaken
Wat zijn de gevolgen
Wat ga ik eraan doen
Wat zijn de normale omstandigheden van het proces
Wat zijn de uiterste limieten van het proces
Hoe zorgt deze schakeling ervoor dat ik mijn veilige toestand bereik.
Wat is het gevolg van het schakelen van deze functie (niet alleen de gewenste)
Hoe snel moet de functie werken.
Te behalen veiligheidsniveau.
….
Doc. Vers.: 4
© Process Automation Solutions NV – An ATS company
Voorbeeld 1
Vrijzetting via seals
LSL 1 stopt pomp P1
Kan een trilvork gebruikt worden om een gevulde pompleiding te detecteren ?
Is er een andere vorm van detectie mogelijk, voordelen, nadelen ?
Wat is dan het probleem met bovenstaande ?
Een motor stoppen in SIL 2 ?
2 contactoren in serie?
Aandachtspunten pompen/motoren.
Doc. Vers.: 4

30. © Process Automation Solutions NV – An ATS company
Voorbeeld 2
Overvullen tank
LSHH-2 / LIAH-1 sluit XV-1
Wat zijn de voor en de nadelen tussen deze opties?
Welke meetprincipe zouden we gebruiken?
Let op met capillairen !
Hoe krachtig moet men actor zijn ?
Elektrische ventielen ?
Doc. Vers.: 4
© Process Automation Solutions NV – An ATS company
Voorbeeld 3
Onderdruk tankwagen
Mangat niet geopend bij aanvang. Meestal geen onderdrukweerstand.
Filmpje.
Welke technische oplossing kunnen we uitwerken met bovenstaande schema?
Terug naar het ontwerp!
Doc. Vers.: 4

31. © Process Automation Solutions NV – An ATS company
Voorbeeld 3
Onderdruk tankwagen: oplossing
Doc. Vers.: 4
© Process Automation Solutions NV – An ATS company
Voorbeeld 4
Runaway door faling koeling
Aandachtspunten met Temperatuurmetingen.
Anekdote.
Hoe kan je borgen dat de koeling goed werkt?
Druk?
Debiet?
Energize/De-energize to trip.
Doc. Vers.: 4

32. © Process Automation Solutions NV – An ATS company
Voorbeeld 5
Hoge druk door overvullen
Snelheid Overdrukken vloeistof?
Regelventiel opnemen in 1oo2?
Lekdichtheid?
Doc. Vers.: 4
Process Automation Solutions NV
An ATS Company
Thank you for your attention.
Doc. Vers.: 4

33. 23/04/2015
Products Solutions Services
Safety by Design
Mechanical integrity ………. safety in the design phase
………. safety in the manufacturing phase
………. safety in the field operation phase
Leading Technologies and Services
for a Safe Plant Operation
Slide 1 Alain ENGELS
23/04/2015
Safety BY DESIGN – A life time 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
• En
• M
• De
• M
• W
• Se
• In
•
•
•
•
••
••
••
Mechanical integrity ……….safety in the design phase
Slide 2 Alain ENGELS

34. 23/04/2015
Endress+Hauser design standards
Slide 3
• Design and testing experience
built on generations of product
history within Endress+Hauser ,
Endress+Hauser customers and
industry/academic organizations
• Costly and unproductive
complexity is avoided by
standardized development across
all Endress+Hauser operations
• These standards help
Endress+Hauser reduce risk in the
design, manufacturing and
documentation of products, in turn
helping us reducing risks to our
customers
Alain ENGELS
23/04/2015
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, graphite, 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 are critical to achieving a low risk service design.
Slide 4
Advanced ceramics &
graphite in high
temperature process
seals
Alain ENGELS

35. 23/04/2015
Design Simulations
Endress+Hauser uses the latest design 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.
stress
strain
elastic area
yield strength
Slide 5 Alain ENGELS
Finite Element Methods
23/04/2015
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 varied 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 weaknesses 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
level at which function or containment is lost
Slide 6 Alain ENGELS

36. 23/04/2015
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.
Slide 7 Alain ENGELS
23/04/2015
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
Showing a customer the complexity in a cross section
picture or model of some of our instruments may help
them grasp there is more mechanical design built in than
what appears from the outside
Slide 8
Advanced ceramics –
graphite process seals
for high pressure and
extreme temperatures
Advanced metallic
spring loaded PTFE
sealing concept.
Alain ENGELS

37. 23/04/2015
Inherently “Safer” designs
Non intrusive measurement technologies
• No mechanical impairment of the process equipment by using non-
intrusive / non-invasive instrument designs
• Radiometric level and density measurements
• Ultrasonic Clamp on flow measurement
• Skin point temperature measurements
Mechanical assemblies with predictable failure modes
Rupture
Disk holder
Predetermined breaking point
Slide 9
Annunciation
Opening behind
second line of
defense
Alain ENGELS
23/04/2015
Safety BY DESIGN – A life time 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
Mechanical integrity ... Safety in the manufacturing phase
Slide 10 Alain ENGELS

38. 23/04/2015
Manufacturing quality assurance
• The quality assurance systems at Endress+Hauser are based on ISO
defined criteria and are regularly audited by outside agencies.
• ISO 9001 Quality Management System
• ISO 14001 Environmental Management System
• OHSAS 18001Occupational Health and Safety Management System
• Each employee in our organization shares the responsibility for
consistently producing the products expected by our customers
• Dedication to quality and continuous quality improvement is cultural
at Endress+Hauser….and our safety message as well!
Reference resources slide for more information and access
Slide 11 Alain ENGELS
23/04/2015
Material traceability
• Maintaining absolute material identification, inventory and
traceability from incoming stock to finished delivered product and
documentation is a core strength of Endress+Hauser manufacturing.
• Material traceability and sometimes proof of traceability is required
by process plant engineering and construction operations to ensure
predictable containment integrity
Slide 12 Alain ENGELS

39. 23/04/2015
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 analyze
• Studies show that in Petrochemical and Refinery facilities almost half of the
largest losses are a direct result of failures in piping systems. PMI testing is
commonly used method to eliminate any material mixing errors
Slide 13 Alain ENGELS
23/04/2015
Radiographic (RT) testing
• Endress+Hauser uses industrial radiography or
X-ray testing to inspect materials for hidden flaws
to reduce risk
• Reveals material defects (visible as well as hidden)
on metallic materials .
• 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.
• Report generated by qualified Endress+Hauser
personnel is included with the instrument
documentation when specified
Slide 14 Alain ENGELS

40. 23/04/2015
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
• LPI is used to detect casting, forging and welding surface defects such
as hairline cracks, surface porosity, leaks in new products, and
fatigue cracks on components
Slide 15 Alain ENGELS
23/04/2015
Welding procedure qualification
• Welding seams on many Endress+Hauser products are produced by automatic
welding machines according to instrument specific WPQR/WPS (Welding
Procedure Qualification Record/Welding Procedure Specification) and
supervised/controlled by approved welding engineers.
• Frequent inspection of both welding machines and the resulting welding seams are
conducted to maintain the highest quality demands and regulatory requirements.
• Customers can fully rely on the welding seam quality of any Endress+Hauser
welded device
Slide 16 Alain ENGELS

41. 23/04/2015
Hydrostatic pressure testing
• Hydrostatic testing is a safer way to verify the integrity of a
manufactured instrumentation component that is designed for
pressure service.
• Many Endress+Hauser components are 100% tested while others are
tested to meet specific customer or industry requirements
Slide 17 Alain ENGELS
23/04/2015
Helium leakage testing
• Leak testing is part of the
Endress+Hauser non-
destructive test NDT portfolio
that can be applied to a
fabricated component to verify
it is leak proof
• For example, Liquiphant
extensions are 100% Helium
tested to ensure component
welding is fully accomplished
and there are no leak points
Slide 18 Alain ENGELS

42. 23/04/2015
Safety DURING OPERATIONS – A life time commitment
• Examples of Endress+Hauser
Mechanical Integrity in field
operations
Mechanical integrity diagnostics
Inherently safer components
Process containment
M
Mechanical integrity ………. Safety in the field operation phase
Slide 19 Alain ENGELS
23/04/2015
Examples of mechanical integrity in field operations
Levelflex
level
Liquiphant
Soliphant
levelswitch
Cerabar/
Deltabar
pressure
Prowirl
Vortex
flow
Leve
le
iTHERM®
StrongSens
temperature
Memosens
Analytical
Promass
Coriolis
Mass flow
Engineered
Temperature
Slide 20 Alain ENGELS

43. 23/04/2015
Liquiphant - Engineering at a glance
Special Features:
• operating temperatures -60 to
280 °C ( -75 to 535°F) (300°C
(570°F) for max. 50 h cumulated)
• pressures up to 100 bar ( 1450 psi)
• highly corrosion resistant material
Alloy C22 (2.4602)
• Including welded-in gas tight feed-
through (second line of defense)
FTL7x
electronic-
insert
Welded gas
tight feed-
through
(second line of
defense)
temperature
spacer part
Ex d -
thread
Piezo-stack drive
vibrating fork
Alain ENGELSSlide 21
The gas tight feed-through prevents e.g. leakage of toxic media
Highest Safety Even in Case of Damaged Sensor
23/04/2015
Soliphant M – engineering at a glance
Improved housing
Smaller
More vibration resistant
through new clamping disk
New seal for F15
Dip switches for
selection of:
Sensitivity
Switching delay
Min/Max function
Diagnosis
Climate seal
NAMUR electronics
New threaded drive
Welding seam is eliminated
Smaller and stronger
316L sensor material
No material mix
Optional abrasive
resistant coatings
2 fork types
Short fork for small tanks
1¼“ NPT diaphragm
Save sensor circuit
SIL 2
Gas-tight feedthrough for
Ex d/de (FTM51, FTM52)
New fork geometry
Stronger root
Slide 22 Alain ENGELS

44. 23/04/2015
Cerabar S/Deltabar S - Secondary Containment
Ceramic Sensor
• gas tight containment to 120 bar (1740 psi)
• diagnostics in DP cell advising of membrane
rupture
Metal Sensor
• pressurized containment (gas tight
feed through, 400 bar (5800 psi) proven)
• completely welded membrane, no seals
Cerabar S
Deltabar S
Differential pressure Sensor
• containment to 1050 bar (15225 psi)
• function control
• withstands alternating loads
Alain ENGELSSlide 23
The gas-tight feed through prevents leakage of medium in case of failure
Highest safety by second process barrier
23/04/2015
Levelflex – FMP54 – Heavy duty under harsh conditions
FMP54
Special Features:
• Robust design and gas tight glass feed-
through
• -196 to +450 °C (-320 to 840 °F)
• Pressures up to 400 bar (5800 psi)
• High diffusion resistance using
ceramic coupling and graphite seal
• Resistant against Superheated steam
(ceramic seal) – application in steam
boilers acc. to EN12952/12953 (NM,
HW, Range)
• Finite element simulations
FMP54
graphite
2nd process
containment
(gas tight glass feed-
through)
••••
graphite
ceramic
Alain ENGELSSlide 24
The gas tight feed-through prevents e.g. leakage of toxic media
Highest Safety at High Pressure and High Temperature

45. 23/04/2015
Proline Prowirl – The reliable multi talent body
Application
example:
Loading of liquid
nitrogen at
-196°C/-320°F
Special features:
Extremely robust basic body
design
Temperatures -200 to 400°C
(-325 to 750°F) (optional
450°C (840°F))
Pressure levels up to PN250/
ANSI 1500 lb
Material stainless steel
(standard), Alloy C-22 (e.g.
corrosive applications)
Proline Prowirl
Shrunk and welded-
in bluff body ensures
safety during steam
hammers
Alain ENGELSSlide 25
High reliability and high life time even under extreme process conditions
(pressure, temperature)
23/04/2015
Proline Prowirl – the reliable multi-talent sensor
Special Features:
• Robust and unique DCS-Sensor
technology
• No aging or wear
• Insensitive versus water hammers
• Highest vibration resistance
(1g at 10…500Hz)
• Insensitive versus temperature shocks
(150K/s)
• Second containment
• Flow rate up to 120m/s (393 fps)
• Proven in use – above 250.000
installed Sensors
DCS = Differential Capacitance Sensor
Gas tight
Glass feed-through
Alain ENGELSSlide 26
Unique DSC-Sensor technology with second containment
High Reliability, Safety and Long Term Stability
containment
HP version
up to 160Bar

46. 23/04/2015
Promass E200/F200 – Two wire-Coriolis-mass meter
Special Features:
• robust housing offers maximum
operation safety in harsh environment
• industrial standards and requirements
consistently realized
Promass E 200 – Standard device lay
length according to NE132 (NAMUR)
Promass F 200 – the market leader in
two wire technology
Alain ENGELSSlide 27
Increases safety and reduces costs for planning, procurement and operation
max. safety with standardized two wire concept
23/04/2015
Memosens is safe in all aspects
Memosens simplifies the operation
• Simply connect the sensors and they deliver reliable values immediately.
• Calibrate the sensors in the lab and exchange them on site in no time.
Memosens increases plant safety
• The inductive plug-in head eliminates all problems due to moisture.
• Digital transmission displays errors actively and enables you to react immediately.
• Simply exchanging the sensors in the field increases availability of measuring point.
Forms the basis for the first certified SIL 2 analytical measurement platform
Highest measuring safety and minimized risk for maintenance staff
inductive signal transfer
inductive energy supply
fety and minimized ri
inductive signal transfer
inductive energy supply
pH/ORP Oxygen Conductivity Chlorine
Slide 28 Alain ENGELS

47. 23/04/2015
Retractable holder–safe port to process for liquid analysis
Cleanfit CPA450 with service friendly safety
locking device:
• holds max pressure up to 12 bar ( 170 psi)
• avoids opening the retractable under
process pressure
Enhanced safety in the insertion position
• lock ring and
• safety locking device made from 316L
Cleanfit CPA472D with safe blocking system:
• No pneumatic positioning in process if a
sensor is not installed
g p
d
Slide 29
E
•
•
C
•
Alain ENGELS
23/04/2015
iTHERM® StrongSens
Robust thermometer with thin film sensor
Special features:
• Robust Pt100 metering sensor with high
vibration resistance for temperatures up to
500°C (60g)
• Robust verified and “calculated” design
Alain ENGELSSlide 30
Unique sensor technology for demanding applications
Longest life time with optimized operation safety

48. 23/04/2015
Thermowell Calculation
Verification of the mechanical strength of a
thermowell for the individual process
conditions.
Calculation according to DIN 43772 or
ASME/ANSI PTC 19.3
Is the thermowell able to withstand the process
conditions?
Static process pressure
Dynamic flow pressure
Flow induced vibrations
Strength of material at process temperature
Slide 31 Alain ENGELS
23/04/2015
Temperature Engineered Solution
Diagnostic and containment chamber –
second sealing barrier
Individual
thermowells –
first sealing
barrier
Connections for diagnostic chamber monitoring
Multipoint with Dual-sealing barriers
Special features:
• Highest plant safety due to dual
sealing barriers
• Safe diagnostic chamber monitoring
under pressure ensures continuous
plant operation
• Replaceable sensing elements
ensures continuous plant operation
• Advanced diagnostics capabilities
Alain ENGELSSlide 32
Dual seal and diagnostic functions ensure …
Safe plant operation in high risk environment

49. 23/04/2015Slide 33
Temperature Engineered Solution– Multipoint TM911
Unmatched safety concept with up to 3 barriers
Safe operation also in fault condition (leakage)
No unplanned shut downs!
Alain ENGELS
23/04/2015
Mechanical integrity planning
• Endress+Hauser provide tools to take risk out of specifying the right
mechanical components for specific service
• Endress+Hauser trained personnel and customers who have the
experience or Endress+Hauser training rely on these tools
Alain ENGELSSlide 34
Applicator
&
Selection Guides

50. 23/04/2015
Products Solutions Services
Any Questions?
Alain ENGELSSlide 35
23/04/2015
Products Solutions Services
Thank you very much
for your attention
Alain ENGELSSlide 36

51. 2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators · 1
SIL in de praktijk (Functional Safety)
23.04.2015 - Antwerpen
SAMSON AG
Dr. Thomas Karte
61508 Compliance of Actuators
and Life Cycle Considerations
2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 2
Applied Physics, University of Heidelberg, Germany
Occupied in the Industry since 1985, general area of field instrumentation, later
specialist in pneumatic instrumentation for valves in the process industry
Joined SAMSON in 2003, since then engaged in Functional Safety
Current position: Head of department for Innovation Management and Patents
Member of VDI-GMA 6.13, Functional Safety, DKE 9.14, IEC TC65 – WG 13
Numerous articles and patents
Dr. Thomas Karte
SAMSON AG, Frankfurt, Germany
+49 69 4009 2086 tkarte@samson.de

52. 2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 3
Main task - Change of Material Flows
Increasing Diagnosis and Asset Management Functions
Control Elements - Complex Field Devices
2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 4
Standard questions and concerns
Certificate for the device / final element in question
What is the failure rate
What is the value for diagnostic coverage
How can evidence of these numbers be given
What is the usefull lifetime
Please, I want to have a SIL 3 valve

53. 2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 5
IEC 61508 and IEC 61511
2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 6
Requirement for subcomponent selection

54. 2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 7
Structure of talk
Causes of Valve Failures
Exclusion of Systematic Errors – Manufacturer Measures
Valve Testing
Design and Implementation of Automated Testing
Numerical Rating
Summary
2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 8
DIN EN 61511 in a nutshell
Failures
Aviodable in principle Unaviodable in principle
Random failuresSytematic failures
FSM-System
Not avoided
Diagnostics
Fail Safe
Redundancy
Probability Calculation
Diagnostics
Fail Safe
diversely Redundancy
Measures sufficient?

55. 2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 9
Safety Life Cycle to avoid Systematic Errors
Quelle: DIN EN 61511-1 - Bild 8
Hazard and risk assessment
1
Specification of Security?
Requirements for the SIS3
Design u.Planung other measures
to reduce risk
Design and planning of
the SIS4
Decommissioning
8
Change
7
Operation and maintenance
6
Installation, commissioning and validation
5
Step 5
Step 4
Step3
Step 2
Step 1
11
Manage-
ment and
assessment
of the
functional
safety
audits
Manage-
ment and
assessment
of the
functional
safety
audits
10
Manage-
ment and
assessment
of the
functional
safety
audits
10
Verifi-
cation
9
Design
and
planning
the
Safety-
life-
cycle
Allocation of safety functions to protection
layers2
2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 10
Main Components of the Final Element
Seat/Disk
Housing
Packing
Seat Ring
Ball
Housing
Globe Valve Ball Valve
SpringMembrane
Solenoid valve
Limit Switch
Positioner

56. 2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 11
Potential Hazards (VDI 2180-5)
Fatigue (e.g. Metal Bellows Seal)
Wear from Cavitation / Flashing
Abrasion (due to material flowing solids)
Deposits of the Medium
Aging: Damage caused by exposure to light and heat,
Organic materials such as plastics and elastomers
Chemical Attack: Damage caused by chemical
extraction & decomposition processes
2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 12
Actuator Reliability, Is a Constant Failure Rate Meaningfull?
Electronics
Statistical Statements on the
Reliability
Controlled Environment
Self-Diagnosis
Methods for accelerated Aging
Mechanics
Macroscopic, accountable System
Media Influence
Environmental Influence
Long term Effects can´t be Accelerated

57. 2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 13
1 ISO 9001 Qualified
2 Quality Manual, Primary Process Development
3 Pressure Equipment Directive 97/23/EG
4 Calculation of Pressurized Parts
5 Materials and Supplier Qualification for Pressure Parts
6 Standard Tests to SAMSON- Globe Valves
7 Quality Management installed that keeps track of field performance
8 Adapting the final element to the specific process – valve seizing
Qualifying Procedures - Manufacturer
2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 14
Fixed R&D Schedule compliant to ISO 9001

58. 2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 15
Pressure Equipment Directive 97/23/EG
2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 16
Calculation of Pressurized Parts
16

59. 2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 17
Calculation of Pressurized Parts
2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 18
Supplier Qualification by SAMSON-Specifications
Minimum Requirement 3.1 - Material Certificate according to DIN EN
10204
100%-Examination of the Pressure-Bearing parts in the Receipt of Goods
Materials and Supplier Qualification for Pressure Parts

60. 2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 19
Standard Test to SAMSON Globe Valves
2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 20
Valve Seizing
Collection of Customer Data in Accordance with DIN EN 60534-7
Collection of additional Information by Echange with Customers
Creating a TV-SK (special design) if necessary

61. 2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 21
Valve Seizing –Permissible Flow Velocities
2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 22
Quelle: DIN EN 61511-1 - Bild 8
Hazard and risk assessment
1
Allocation of safety functions to protection
layers2
Specification of Security?
Requirements for the SIS3
Design u.Planung other measures
to reduce risk
Design and planning of the SIS
4
Decommissioning8
Change
7
Operation and maintenance
6
Installation, commissioning and validation
5
Stufe 5
Step 4
Step3
Step 2
Step 1
1
1
Management
and
assessment
of the
functional
safety audits
Management
and
assessment
of the
functional
safety audits
1
0
Management
and
assessment
of the
functional
safety audits
1
0
Verifi-
cation
9
Safety Lifecycle to Avoid Systematic Errors
• Periodic inspection and testing
• Examination during operation
• Documentation system failure
Validation
Design
and
planning
the
Safety-
life-
cycle

62. 2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 23
Safety life cycle at customer side
Specification of safety requirements
Selection of suitable components
Manufacturer declaration
Valve seizing (fit to the specific process)
Proven in use statement highly recommended (NE 130)
Consideration on reliability
Defined procedures for inspection and testing
Trained personal
Documentation of all steps
2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 24
What is the safety requirement
The final element shall shut down or open the pipe
Leakage rate
Time response
Keep specifications as wide as possible
This has major influence on testing and diagnostic

63. 2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 25
Namur recommendation NE 130 „Proven in use“
• NE 130 provides clear
definition for
„proven in use“
• Instrument
performance for a
specific application is
rated
2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 26
Failure rates provided by NE 130
Based an data generated by NE 93
Survey on a voluntary basis within NAMUR companies
Applicable for proven in use devices

64. 2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 27
Process equipment datasheet (VDI 2180 – Part 5)
• Valve seizing process
to adapt to specific
application
• Guided by VDI 2180-5
(example)
2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 28
How is a Valve Tested
From the Manufacturer
Items
Leak Test
Pressure Test
Functional Test
In the plant
Inspection after 61508 (Plant Tour, Visual Inspection)
Functional Test during Non-Operating Times
(Parameters: Function, Closing Time, End Position)
Functional Testing under Load (+ leaks)
Standard requires Testing under Operating Conditions

65. 2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 29
3730 Positioner
Solenoid valve, Limit
Switches and
Positioners Diagnostic
Capability in a Housing
Diagnostics
Automatic Monitoring
during Operation
Automation Options
3738 Intelligent Limit Switch
Solenoid Valve,
Limit Switches
Certified Safety Function by
TÜV
Automatic Monitoring during
Operation
Solenoid Valve,
Limit Switches
2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 30
• Suitability for Safety-
related Circuits
• Shutdown over 4 mA
• Reduced Cabling Costs
Positioner as a Single Automation Component
Safety-related Control Positioner
Position Feedback Positioner, Analogue
Pressure Measurement Positioner, Analogue
Automation Valve Test Positioner
Test Coverage Pneumatic yes

66. 2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 31
Automated Testing
Result:
Functional Test
Path-time Diagram
Dead time, run-time
Breakout Force
Exact closed position
ALARM
Reproducible Implementation:
Valve movement is initiated
Positioner Internal Measurement
of the Valve Motion
Valve Motion is Recorded
Dokumentation:
Registration of the Event
Numerical Results
Path-time Diagram
Good / Bad Review
2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 32
Periodic Inspection
Solution:
Functional Test
Travel-time Diagram
Dead time, Run-time
Breakout Force
Exact Closed Position
ALARM
Rating:
Ability to move
Breakout Force
Travel-time
Tightness (from closed position)
Implementation:
Manually triggered
Automatic test without
user interaction

67. 2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 33
Testing During Operation
As an additional Security Measure, or to check during Operation
Result:
Functional Test
Path-time Diagram
Dead time, Run-time
Breakout Force
Exact Closed Position
ALARM
Rating:
Ability to move
Breakout Force
Travel-time
Tightness (from closed position)
Implementation:
Manually or automatically
triggered
Automatic test without
user interaction
2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 34
Examination during Operation, Friction Detection

68. 2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 35
Capture of spurious trips
Result:
Functional Test
Travel-time Diagram
Dead time, Run-time
Breakout Force
Exact Closed Position
Alarm
Implementation:
Triggered by valve
movement
independent data
collection
Rating:
• Ability to move
• Breakout Force
• Travel-time
• Tightness (from closed position)
2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 36
Bauformen SIL 2
(Final element 50%)
Safety margin
PRTPFD ⋅= λ
2
1
0,0000
0,0025
0,0050
0,0075
0,0100
0 6 12 18 24
Prooftest [month]
PFD
PFD
SIL2-Grenze
Extended Operation Time by Online Testing

69. 2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 37
Bauformen SIL 2
(Final element 50%)
Safety margin
PRPST TDCTDCPFD ⋅−⋅+⋅⋅= )1(
2
1
2
1
λλ
PRTPFD ⋅= λ
2
1
0,0000
0,0025
0,0050
0,0075
0,0100
0 6 12 18 24
Prooftest [month]
PFD
PFD
PFD PST
SIL2-Grenze
PST
Extended Operation Time by Online Testing
2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 38
2180-3 ( 3.4.1) and IEC 61511
Analysis of the records is mandatory
Documentation for the operating experience regarding any problems
Potential for improvement: new devices with more favorable properties
Option to extend the proof time
Optimization of Safety Loops
Aus Paul Gruhn, „Safety Shutdown Systems“

70. 2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 39
Trending
2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 40
Error Images and Diagnostic Coverage
Component Failure Mode Recognizability
Diagnostic Possibility
Positioner
Seat/Disk
Corrosion
internal/external
Flow measurement, diagnosis
STR, disassembly
acoustic leak sensor, zero offset
(driving force, friction)
Fatigue (e.g. Metal
Bellows Seal)
not applicable not applicable
Wear from
Cavitation /
Flashing
Flow measurement, diagnosis
STR, disassembly
acoustic leak sensor, end
position trend (Zero Point offset),
(driving force, friction)
Abrasion
Flow measurement, diagnosis
STR, disassembly
Deposits of the
medium
Flow measurement, diagnosis
STR, disassembly
Aging not applicable not applicable
Chemical Attack not applicable not applicable
mechanical stress
Flow measurement, diagnosis
STR, disassembly
acoustic leak sensor, end
position trend (Zero Point offset),
(driving force, friction)

71. 2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 41
Normative Requirements: Defined
Processes, Documentation, Diagnostics
Coverage
Summary
Safety Life Cycle is supported by state of the
art instrumentation
Systematic failures are dominant – as a
consequence Safety Life Cycle is the most
important isssue
41
2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 42
61508 Compliance for Actuators
THANK YOU
FOR YOUR ATTENTION !