Gas detector at safety integrity level.

A new GD1 laser-based gas detector, with full SIL2 3rd party approval, has been unveiled by Teledyne Gas and Flame Detection (GFD). This ground-breaking development means that the GD1 SIL2 is the market´s first open-path gas detector for hydrogen sulphide (H₂S) safety-related applications.

The global importance of SIL (Safety Integrity Level) has grown substantially in the oil, gas, petrochemical and other process industries over the past 10 years. It makes sense, therefore, that devices such as gas detectors demonstrate their suitability and competence in line with the latest SIL2 third-party certification.

The GD1 from Teledyne GFD first entered the market in 2011, with well over 1600 units since deployed at oil and gas exploration and production (Onshore & Offshore) companies throughout the Middle East and the rest of the world.

With its new certification, the GD1 is now suitable for use in systems with SIL2 requirements. To provide some context, a typical SIL1 ATEX-certified gas detection device/system will come complete with the functional approval according to IEC 60079-29-3 and require regular maintenance. The step from SIL1 to SIL2 requires built-in automatic self-testing of hardware components and this means reduced maintenance intervals for sensors, and reduced downtime.

GD1 complies to the latest standard for IEC 60079-0:2017 (IECEx).

Teledyne GFD´s innovative GD1 will prove attractive in SIL2 applications for several reasons, not in the least its unique customized tunable laser diode that eliminates environmental effects from sun, rain or fog. In fact, the GD1 can operate with up to 98% obscuration, boosting overall site safety. This capability is possible because light emitted by the detector travels as a cone from one point to another, rather than as a conventional straight beam. In other words, the beam expands after transmission and is almost a meter in diameter when it reaches the receiver mounted 75m away. It can therefore penetrate harsh environments that competitor solutions may find difficult.

With its fast and fail-safe laser, the GD1 performs real-time dual automatic calibration and automatic proof testing, thus eliminating the need for manual intervention and reducing maintenance costs. Further advantages include low power consumption (15W), very long lifespan and a high sampling/detection rate of 8000 times per second thanks to its ultra-stable optomechanical construction.

All these added-value characteristics mean the GD1 can replace multiple standard detectors to cover the same risk, making it an economic solution that typically demonstrates real cost savings within two years.

@mepaxIntPR #TeledyneGFD #PAuto #Safety

SIL tool for intelligent servo drives.

Elmo Motion Control’s Platinum series advanced servo drives feature EtherCAT™ networking for ultra-fast machine synchronised single and multi-axis motion, and industry leading levels of functional safety. These impressive drives are now available with Elmo’s free-to-use Motion Composer2 tool allowing machine designers to easily develop, test and implement user-specific motion and machine control algorithms as drive level SIL (Software in the Loop) commands. 

Elmo Motion’s Platinum series advanced servo drives – available with Servo in the Loop (SIL) from Heason* technology 

Integrated as a module within MathWorks® Simulink® Real Time Workshop, Motion Composer2 features an assortment of servo performance, motion profiling, communications, and robot kinematics-based library blocks that are assembled, cross-compiled and downloaded to the Platinum drive. Enabling rapid time to market with fast performance-optimised algorithm development, individual library blocks are easily modified with comprehensive evaluation and system level simulation aided by ELMO’s EASII Application Studio.

The integration with the Real Time Workshop allows access to measurement devices such as inertial sensors, gyros and IMUs as well as a host of machine control I/O devices, hardware components, and sub-systems from a wide range of manufacturers. Users can develop their preferred communication protocols over serial links in real-time and kinematic transformations are easily designed and implemented.

This series covers four intelligent drive designs with single-axis as well as 4-axis servo capability. Through the range, typical continuous power levels to 2 kW and qualitative power levels to 5.0 kW are available (up to 22 kW coming soon). All Platinum series drives feature industry leading processing capability channelled through EtherCAT with cycling down to 100 microseconds. These impressive cycling rates provide the basis for unparalleled motion synchronisation and the potential for Software in the Loop processing provides a platform for extremely demanding high speed and high throughput motion-centric automation applications across industry, research, and defence. As well as their SIL capability, Platinum series drives also offer comprehensive functional Safety and FSoE certification. For straightforward application development, ELMO’s EASII Application Studio software also manages EtherCAT configuration, motion configuration, drive tuning, parameter recording, monitoring, and much more.

*With several years’ experience with Elmo Motion and supported by its own in-house design and build capability, the British distribution partner Heason supplies and supports Elmo’s full range of servo drives and controls as separate motion components or as part of custom-designed motion systems complete with positioning and drive transmission mechanics.

@heasonmotion @ElmoMotionContr #Pauto #Transportation

Infrared gas detector.

The only device on the market that provides IR detection to first-class SIL 2 high demand mode and SIL 3-capable IEC 61508 ed. 2 with a proof test interval of 8760 hours.

Teledyne Gas & Flame Detection has provided its GD10P infrared gas detector with a full firmware revision and upgrade, enhancing the product’s performance in high demand mode SIL2 approved applications. This milestone, as part of the product’s continuous improvement lifecycle, builds on circa 30 years of proven field experience for GD10P in the harshest industry environments and further supports the provision of a far longer warranty than conventional infrared gas detection systems.

Functional safety
New firmware within GD10P complies with the highest functional safety standards. The safety function has been assessed in conformity with the IEC 61508 ed. 2 standard according to Route 1S: Requirements for the avoidance (prevention) and requirements for the control of systematic faults, as well as Route 1H, which is based on hardware fault tolerance and safe failure fraction concepts.

High demand mode is where the frequency of demands for operation made on a safety-related system is greater than one per year.

While most safety-based applications in the process sector require only ‘low demand mode’ solutions, ‘high demand mode’ safety-critical applications are becoming increasingly common. As a result, gas detectors such as the GD10P must demonstrate their suitability and competence in line with the latest SIL2 third-party certification.

Solid-state infrared source
In comparison with other infrared (IR) gas detectors, the new firmware adds further to GD10P’s differentiating factors, which include a solid-state infrared source. Here, the optical chamber, featuring two independent IR silicone (semiconductor) sources, is sufficiently robust and stable to merit a 15-year warranty. This compares favourably with the standard 2-3-year warranty commonly available with conventional IR detectors. The GD10P also features heated optics to prevent condensation, a HART interface, fail-safe operation, extended diagnostics and low maintenance requirements thanks to features such as a scratch-proof sapphire lens/mirror (instead of traditional glass).

Whereas 2-3 measurements per second is the norm with many IR gas detectors, the GD10P can perform 50 measurements per second. More sampling means less false alarms, higher accuracy, faster response time and, in turn, lower operational costs. Further cost reductions arrive as the fit-and-forget GD10P requires no calibration. In contrast, conventional IR gas detectors require calibration twice a year.

Thanks to its solid-state dual sources, the GD10P, which has origins in the oil and gas industry, is ideal for use in extremely hot, cold or wet environments. Conversely, traditional alternatives suffer negative effects from factors such as vibration, flow rate and environmental influences like heat and dust, which means their plastic filter/sinter can melt or clog. Other noteworthy advantages of the GD10P in comparison with conventional gas detectors include a calculated life of 60 years (versus five years) and a T90 response = 1 second for methane (versus >8 or 9 seconds). 

Proven in the field.
Among countless real-life applications, one worth calling out is the detection of ethylene in recirculating air on board large industrial machines. Most applications of this type now require SIL2 level gas detection in high demand mode, and GD10P offers this feature without hardware redundancies. This particular application requires high accuracy that would otherwise necessitate specific process monitoring measures beyond safety devices alone. However, the GD10P matches the requested accuracy, allowing the customer to make savings in equipment investment costs as each machine required multiple detection points.

Another common example of the GD10P’s aptitude is evident in the detection of propane at industrial welding stations. After a previously unsatisfactory experience using catalytic detectors, the GD10P is proving ideal in these dusty conditions thanks to ‘auto-zero’ self-adjustment of the detector. Furthermore, the large optical chamber provides the opportunity to send two different warning levels that indicate the requirement for cleaning and avoid the need for ‘real time’ servicing.

Further exemplifying the benefits of GD10P is its application involving the detection of ethanol when monitoring the storage of perfume essence. The aim was to avoid the loss of expensive perfume essence diluted in ethanol, perhaps due to a tank leak, and avoid the increase of ethanol concentration in a confined area. The GD10P, due to its target gas selectivity (narrow band optical filter) and very low response time, was the optimum solution. The detectors have been in service for four years.

Low cost of ownership
These and many other case examples build upon a large global installed base of more than 100,000 GD10P IR gas detectors, many of which are operating in harsh conditions. Lower cost of ownership is a further advantage as only one detector is required per system, instead of several with low demand mode SIL2 approval.

Notably, the firmware upgrade aligns Teledyne’s GD10P with the requirements of the latest third-party certification advancements, increasing confidence in the platform’s traditional feature sets. When coupled with a depth of innovation based on real world data from in-field proven use over several decades, the GD10P knows few limitations, irrespective of the application’s size, environment or location.

@mepaxIntPR #Teledyne #PAuto #Infrared

Shutdown valves in critical SIS applications.

Fisher™ Digital Isolation™ solutions are SIL-certified as full assemblies by exida and can improve critical performance specifications in safety instrumented systems by up to 50%. 

The first valve assemblies that meet the design process requirements of Safety Integrity Level (SIL) 3 per the International Electrotechnical Commission’s IEC 61508 standard have been introduced by Emerson. These Fisher™ Digital Isolation™ final element solutions serve the needs of customers for shutdown valves in critical safety instrumented system (SIS) applications.

Without this solution, users must specify all the individual valve components, procure each one, and assemble them into a working whole. Even if these steps are done correctly, this type of custom assembly will still not provide all the benefits of the Digital Isolation assembly.

“We were excited to work with Emerson to accomplish the first certified valve assembly,” said Loren Stewart, exida evaluating assessor for this project. “By providing a complete SIL solution for valve assemblies, Emerson is reducing unknown variables while helping ensure safety is always paramount.”

Engineering a safety shutdown valve is a complicated task. The normal and upset process conditions must be carefully evaluated and understood when choosing valve and actuator components. In addition, the proper combination of solenoids, brackets, couplings and other critical hardware must be specified and carefully matched to the selected valve. Each of these components must function individually and in concert to operate.

Emerson addresses these and other issues by providing an engineered Digital Isolation shutdown valve assembly, designed for each particular process. The various components are specifically selected to satisfy the application requirements. The entire assembly is sold as a fully tested and certified unit, with a single serial number and associated documentation delineating the details of every part of the assembly.

Because the assembly is built as a complete solution in Emerson facilities, it boasts a significantly improved probability of failure on demand (PFD) rate. In some cases, the failure rate of the assembly will be up to 50% less than the combination of the same valve components purchased individually and assembled by an end user.

This improved PFD results from the assembly being certified as a whole system by exida, a global leader in product certification and knowledge, to meet their rigorous Remote Actuated Valve Assembly requirements. By using this certified assembly, SIS designers may realise a substantial reduction in dangerous undetected failure rates (λDU).

In one example, an Emerson customer was hoping to achieve a six-year test interval for a SIL 2 safety interlock. When they performed a component SIL calculation on a standard shutdown valve, they could only achieve a SIL 1 level reliability at a six-year test interval. However, the Digital Isolation assembly exceeded SIL 2 requirements using the same components. This allowed the plant to safely extend their run time to six years, generating millions of dollars in additional revenue.

@FisherValves @Emerson_News @HHC_Lewis #PAuto #Safety

Safe current drivers.

Pepperl+Fuchs is completing its portfolio of SIL 3 isolated barriers for all types of signals—both as modules for DIN rail mounting and as isolating components for termination boards. Positioners in a SIL 3 application—which have always been available for digital signals from or into the field, and for analog measuring signals—can now be connected directly to the controller with a single interface module. A SIL 3 application must no longer be realized via the elaborate path of redundant SIL 2 devices.

SIL 3 applications are also widely used in safety-related applications in which field devices in hazardous areas must be controlled using analog signals. However, no suitable isolated barriers with the ability to transmit signals between the controller and field devices have been developed to date. It may be possible to put a workaround with redundant SIL 2 devices in place. A SIL 3-compatible interface module would require significantly less effort compared to a structure comprising two redundant SIL 2 modules. Last but not least, isolated barriers with SIL 3 suitability can even be useful in SIL 2 applications, for example, when the longest possible proof time is to be achieved.

The new, single-channel current drivers have a width of 12.5 mm, line fault detection, and a separate fault output. This allows users to build SIL 3 applications from a single portfolio, whether with SIL 3 isolated barriers or with redundant, SC3-capable SIL 2 modules.

A product selector for safety products can be found at www.pepperl-fuchs.com/safety-hub. This selector can be used to select suitable devices by function, signal type, SIL level or performance level (safety relays for safe shutdown both have SIL and PL levels).

@PepperlFuchs  @mepaxIntPR #Pauto #Safety 

VA meter switch.

Krohne's variable area (VA) flowmeters DK46/47/48/800 with glass tube are now available with SIL 2 compliance. They are the first and currently the only SIL 2 glass tube purgemeters on the market.

The SIL option is applicable for devices with stainless steel or brass process connections with bistable NAMUR limit switches and junction box. It can be combined with ATEX certifications and also applies to VA flow controllers with individual probability of failures.

Typical applications for the SIL 2 glass tube flowmeters are sample flow monitoring for process analyser systems, gas or liquid supply monitoring for mechanical sealing systems, purging monitoring for measuring systems (e.g. dP flow measurement), or nitrogen inertisation.

@krohnegroup #Pauto #SIL

Compact flow meter to meet SIL requirements.

New Rosemount™ 8800 Quad Vortex meter is designed with built-in redundancies for SIL 3 safety requirements along with basic process control, and fits into less than half the space of four traditional redundant flow meters, offering easy, cost-effective installation.

Emerson has introduced the Rosemount™ 8800 Quad Vortex flow meter specifically designed to meet stringent safety standards in environments and applications that require safety instrumented systems (SIS). The flow meter is the first in the industry with quadruple sensors and transmitters to meet safety integrity level (SIL) requirements. Comprised of multiple independent sensors in an all-welded meter body, the meter provides a compact flow solution with built-in redundancies for added safety without introducing intentional leak points. The meter reduces piping needs threefold by eliminating the additional flanges and pipe runs required for the installation of multiple flow meters in a redundant flow measurement solution.

“Our refining and chemical customers who have tested this new flow meter have found tremendous value from this unique and differentiated flow solution,” said Julie Valentine, refining industry flow solutions director for Emerson’s Automation Solutions business. “The 8800 Quad Vortex flow meter has made the specification, purchase and installation of a SIS/SIL application with reduced piping and space requirements easier than ever before.”

With the ability to meet measurement challenges in industries such as chemical, power, refining, and offshore oil and gas applications, particularly where space is limited, and safety is crucial, the Rosemount 8800 Quad Vortex flow meter can take the place of multiple individual flow meters. The Rosemount 8800 Quad Vortex flow meter accomplishes the same task as four separate meters, without needing impulse lines that might clog. The meter saves money by reducing installation costs as a simple all-in-one drop-in solution.

The Rosemount 8800 Quad Vortex flow meter’s design and configuration allows for a SIL 3-capable solution and protects against spurious trips using a two out of three (2oo3) voting method. The 2oo3 voting method ensures that at least two of the sensors must read ‘good’ for a process to continue, which means one poor reading does not trip a complete process shutdown.

@EMR_Automation @Rosemount_News @Emerson_News @HHC_Lewis #PAuto

Vibration monitoring delivers machinery health.

To help users further enhance the reliability of rotating assets, Emerson has upgraded its portfolio of machinery health monitoring systems to deliver asset protection and fault prediction in more places and with faster response than ever before.

Both the AMS 6500 Machinery Health Monitor and AMS 2600 Machinery Health Expert systems have been redesigned to improve performance and fully comply with the European Union’s Restriction of Hazardous Substances (RoHS) Directive and Registration, Evaluation, Authorisation, and Restriction of Chemicals (REACH) Regulation. In addition, the AMS 6500 ATG protection system has been certified as meeting the International Electrotechnical Commission’s (IEC) risk reduction requirements for safety integrity level (SIL) 2, giving users added assurance that it will reliably deliver appropriate insight into the health of critical assets.

The newly redesigned systems will include Modbus™ compatibility and Emerson’s patented PeakVue™ technology as standard features. Field-proven to be an effective and reliable indicator of mechanical damage severity, PeakVue filters out most vibration signals to focus on impacting, providing more effective and reliable indicators of overall asset health.

“Online monitoring helps organisations stay aware of moment-to-moment asset health, particularly on their most critical assets,” said John Turner, product manager for online prediction at Emerson Automation Solutions. “New features in the AMS product portfolio will give users essential and timely online monitoring data and help to improve compliance, even under the most restrictive conditions.”

The AMS 6500 and AMS 2600 systems, which help users effectively plan maintenance, now meet IEC 60068 standards for withstanding shock and vibration, allowing users to safely deploy them in harsh environments where ambient vibration and possible electrical shocks present the risk of damage, such as on wind turbines. A new processor boots faster, and the solid-state drive (SSD) technology can handle transient file transfer 10 times faster, resulting in improved and more responsive asset prediction and process health analysis.

The new processor requires AMS Machinery Manager 5.61 with a firmware patch, or any higher version of AMS Machinery Manager. The AMS 6500 ATG advanced prediction application is compatible with AMS Machinery Manager 5.7 or higher. AMS 6500 prediction monitoring system cards are backwards compatible with all AMS 6500 hardware systems.

The AMS 6500 ATG system, which features embedded predictive diagnostics and optional advanced prediction capabilities, has received SIL 2 certification. Whether organisations need certified equipment to meet company guidelines or to comply with legal requirements, SIL ratings help users evaluate whether a specific technology meets the selected risk tolerance for essential equipment such as steam and gas turbines in power plants or critical refinery and nuclear industry assets.

“More and more organisations are finding they need SIL certified products to meet international standards and machine directives,” said Björn Müller, product manager for online systems and sensors at Emerson Automation Solutions. “SIL certification is one more way we can help customers achieve compliance while demonstrating our commitment to risk reduction.”

@EMR_Automation  #PAuto #MachineryHealth

SIL certified Vortex flow meters.

Facilities with safety instrumented systems can now take advantage of the new SIL 2/3 functional safety certification of Emerson’s Rosemount™ 8800 Vortex flow meters, per IEC 61508, which can help mitigate risk, enhance plant safety, and protect personnel.

“The new addition of SIL 2/3 certification allows Emerson to offer the most comprehensive Vortex portfolio to address the importance of plant safety, process availability, and measurement stability,” said Wally Baker, director of product marketing for Rosemount Vortex flow meters.

The non-clog Rosemount 8800 Vortex portfolio offers safety and reliability features such as online removable sensors to reduce process downtime and a critical process valve for aggressive applications which increases personnel safety by preventing exposure to hazardous fluids. A variety of configurations are available to suit a variety of requirements, including flanged, wafer, reducer, dual, and quad meter body styles, supporting installations up to 12in (300mm) line sizes.

Per an accredited third-party assessment, a single Rosemount 8800 Vortex meter may be used up to SIL 2. The Dual Vortex meter is capable of up to SIL 3 and offers a simple drop-in solution to reduce installation costs. This configuration includes a single or dual shedder bar(s), dual sensing elements, and dual transmitters for redundancy and 1oo2 voting to reduce unexpected shutdowns.

Exclusive to Emerson, the Rosemount 8800 Quad Vortex uses a dual shedder bar, quadruple sensor, and quadruple transmitter configuration to meet hardware fault tolerances and eliminate the need for multiple flow meters. This option offers the highest level of reliability to guard against spurious trips using 2oo3 voting and includes a fourth transmitter for process control.

@EMR_Automation #PAuto @Emerson_News #Safety

Modular safety system (SIL3).

Following its recent certification as Ireland’s first and only Siemens Factory Safety Specialist, (see our story "Unique recognition in Ireland" May 2017), Douglas Control and Automation are showcasing the Siemens safety PLC range.

Safety PLC (CPU 1512SP F-1 PN) fully modular safety 

system delivered by Douglas Control and Automation.

There are Fail-safe controllers in all the Siemens PLC ranges that provide flexibility and compatibility with existing installations. These are capable of complying with safety standards, IEC 62061 up to SIL 3 and EN ISO 13849-1 up to PL e.

Siemens Fail-Safe PLC models
The S7-300F and S7-400F are programmed with Distributed Safety on the SIMATIC Manager platform. The latest S7-1200F, S7-1500F and ET200F CPUs are programmed with Step7 Safety integrated in the TIA (Totally Integrated Automation) environment.

Douglas provides full functional safety design, configuration and testing services for both the Process and Machine sectors. Engineers certified by TÜV as Functional Safety Professionals (FSP) in accordance with both IEC 61511 (Process) and IEC 620161/ISO13849 (Machinery) can deliver proven solutions from the simplest emergency stop system using safety relays to fully integrated safety PLC systems.

@DouglasControl  #PAuto #Safety @siemensindustry 

Whole wireless gas detection system.

The ProSafe-RS® SIL2 wireless gas detection system is to be released by Yokogawa in September. Established by the International Electrotechnical Commission (IEC), a safety integrity level (SIL) indicates the relative level of risk provided by a safety function. SILs 1 through 4 are defined by IEC 61508. At SIL2, the risk factor for a plant where safety measures are not in place is in a range between 1/100 and 1/1,000. At SIL3, the risk factor is in a range between 1/1,000 and 1/10,000.

The ProSafe-RS SIL2 wireless gas detection system will consist of a newly enhanced version of the Yokogawa ProSafe-RS SIL3 safety instrumented system (R4.03.10), their field wireless network devices, annunciator panels, and subsidiary of the German company Drägerwerk AG & Co., GasSecure, wireless gas detectors GS01 or the GS01-EA which is equipped with an extension antenna.

Thus Yokogawa is to establish a total solution that will include both consulting and engineering.

Development Background
In energy and basic materials industries such as oil & gas, petrochemicals and chemicals, a safety instrumented system is employed to safely initiate an emergency plant shutdown when a critical failure is detected, and to initiate the operation of facilities that can extinguish or prevent the spread of a fire.

A field wireless system consists of field devices that are able to communicate wirelessly with a monitoring and control system. Wireless devices have a number of advantages such as allowing installation in difficult-to-access locations and the reduction of installation costs, and they are increasingly seen as essential elements in plant safety solutions. This is a particularly important consideration with gas detection systems, as operation can easily be impacted by factors such as installation location and ambient conditions. And even after system installation, ongoing efforts to optimise its overall configuration may necessitate occasional changes in the location and number of detection devices. The use of wireless technology eliminates the need to worry about wiring and thus greatly facilitates the process of moving and/or installing additional detection devices.

To achieve SIL2 level risk reduction when using wireless gas detectors with a safety instrumented system, communication protocols that comply with the functional safety requirements specified in the IEC 61508 international standard are required. A standard for the functional safety of electrical/electronic/programmable safety-related systems. To meet this need, Yokogawa will provide a SIL2 wireless gas detection system based on a new version of the ProSafe-RS safety instrumented system that will link to field devices using an IEC 61508 compliant communication protocol.

Features of the System

The ProSafe-RS SIL2 wireless gas detection system will consist of a new version of the ProSafe-RS safety instrumented system, R4.03.10, that will be enhanced to add support for an IEC 61508 compliant safety communication technology used in distributed automation; annunciator panels; ISA100 Wireless compliant field wireless devices; and GasSecure GS01 or GS01-EA wireless gas detectors, which are the only devices of this type in the industry that achieve SIL2 risk reduction. The ISA100 Wireless network protocol is based on the ISA100.11a wireless communication standard for industrial automation that was developed by the International Society of Automation (ISA), and the applications necessary for its implementation. This was approved as the IEC 62734 international standard in October 2014.

1. Total system solution including both consulting and engineering Through the use of wireless technology, the ProSafe-RS SIL2 wireless gas detection system will allow increased flexibility with the configuration of detection devices, and will be suitable for use as a fire & gas system and emergency shutdown system thanks to its achievement of SIL2 risk reduction. Based on its knowledge of each of this system’s components and its expertise in production control, safety instrumentation, and field wireless engineering and consulting, Yokogawa will be able to offer a total system solution that includes customer support. 

 2. Enhanced operating efficiency On their Yokogawa CENTUM® VP integrated production control system screens, operators will be able to easily monitor the operation of the ProSafe-RS SIL2 wireless gas detection system as well as that of any conventional wired gas detection system. Since the GasSecure GS01 or GS01-EA wireless gas detector uses the same faceplate as a wired gas detector, operators will have no trouble identifying any changes in the detector’s status, thus helping to prevent errors that can result from the misinterpretation of information. 

3. Improved maintenance With CENTUM® VP, operators will have on-screen access to information on the status of all network devices, the charge remaining on the gas detector batteries, and the status of wireless communications, and thus will be able to quickly detect and respond to any abnormality. Thanks to this functionality, more efficient maintenance plans can be drawn up that, for example, will require fewer periodic checks.

Released in February 2005, the ProSafe-RS safety instrumented system helps prevent accidents by detecting abnormal conditions in plant operations and initiating emergency actions such as a plant shutdown. An independent certification body has certified that ProSafe-RS can be used in SIL3 applications. Unlike conventional safety instrumented systems and distributed control systems, which are regarded as having different roles and functions and operate separately, the operation of ProSafe-RS and the CENTUM integrated control system can be fully integrated. ProSafe-RS is highly regarded by users and has been installed in more than 2,100 projects worldwide (as of June 2017).

Yokogawa’s Commitment to the Field Wireless Business
Yokogawa developed wireless communication technologies for continuous processes that necessitate advanced control and released the world’s first ISA100 Wireless system devices in July 2010, thereby offering its customers a wider range of products to choose from. Currently, Yokogawa offers its customers in the oil & gas, and other industries a wide range of field wireless management stations, field wireless access points, wireless field devices, and wireless adapters for conventional wired devices.

Major Target Markets and Applications
For use in fire and gas systems (FGS) and emergency shutdown systems (ESD) in process industries such as oil, natural gas, petrochemicals, chemicals, pharmaceuticals, electric power, and iron and steel.

@YokogawaIA  #PAuto @DraegerNews

SIL 3 certified single controller for water and steam.

Emerson’s water and steam detection system is the world’s first single controller solution to be certified to IEC 61508 for safety instrumented functions up to SIL 3.

The Mobrey™ Hydratect™ 2462 Water and Steam Detection System is used in a wide variety of applications where the detection of water or steam is vital for safe and efficient plant operation, such as boilers, steam drums and steam line drain pots. This helps to protect valuable plant assets, prevent downtime, save costs and improve worker safety.

The functional safety assessment performed by Exida enhances Hydratect’s reputation for reliability and durability. Exida, world leaders in functional safety certification, have assessed Hydratect and determined that it meets the requirements of SIL 3. The Hydratect system is ideal for the most demanding applications within power generation, refineries, chemical, steel, pulp and paper plants. It can operate in process conditions of up to 300 bar and 560°C. Failure of equipment in such applications can have serious consequences – the Hydratect offers the benefit of SIL 3 approval guaranteeing its reliability.

Hydratect is a modern replacement for conventional float switches, and consists of a compact twin-channel electronic unit, connected to a pair of electrodes. Each channel gives independent indications of the presence of water or steam that are more reliable than those obtained with electro-mechanical devices, which have the possibility of failing in an unsafe condition. By installing the electrodes in vessels or steam lines and measuring the resistance, the presence of water can be detected, allowing appropriate safety measures to be taken.

By detecting low water level in steam drums, Hydratect helps to prevent boiler tubes overheating, which could lead to an explosion, while detecting high water level prevents the generation of wet steam which could cause costly turbine blade erosion. Using Hydratect to detect water in steam line drain pots, as part of a turbine water induction prevention system (TWIP), helps prevent damage to turbine blades, cylinders and the housing.

The electronics unit provides a local indication of steam, water and fault states, and features configurable fault and trip outputs. Component failure, cable faults, ground faults and electrode problems are continuously self-monitored. Additional reliability is provided by triple redundancy of critical components, which ensures that failures result in a safe condition. An individual power supply to each channel further enhances reliability.

@EMR_Automation #PAuto #SIL @HHC_Lewis

Safety instrumented system enhancement announced.

The ProSafe-RS safety instrumented system from Yokogawa has helped prevent accidents by detecting abnormal conditions in plant operations and initiating emergency actions such as a plant shutdown since 2005. An independent certification body has certified that ProSafe-RS conforms to the IEC61508 international safety standard and can be used in SIL3  applications. Unlike conventional safety instrumented systems and distributed control systems, which are regarded as having different roles and functions and operate separately, the operation of ProSafe-RS and the CENTUM integrated control system can be fully integrated. ProSafe-RS is highly regarded by users and has been installed in more than 2,100 projects worldwide (as of April 2017).

The company is about to release (April 26) an enhanced version of the ProSafe®-RS safety instrumented system. This latest release, R4.03.00, includes an improved engineering function for configuring fire and gas systems (FGS) and new operation faceplates for the FGS operation and monitoring screens. These enhancements make it easier to adopt and use ProSafe-RS in FGS applications.


Development Background
In the oil, natural gas, petrochemical, chemical, and other energy and basic materials industries, various safety measures must be taken to prevent accidents and protect the environment. This includes the use of a safety instrumented system, which can secure plant safety by functioning as an emergency shutdown system (ESD) that detects abnormal conditions and safely initiates emergency shutdowns, and by functioning as an FGS.
Yokogawa’s ProSafe-RS safety instrumented system can be integrated with the CENTUM VP integrated production control system and is widely used mainly in ESD applications all over the world. Based on an April 2017 Yokogawa survey, ProSafe-RS is one of the top selling safety instrumented systems on the market today. Since releasing this system in 2005, Yokogawa has continued to strengthen its functions to satisfy a variety of customer needs. In response to the rising need for FGS solutions, this latest release includes features that make it easier to adopt and use this system in such applications. And by adding a new input/output (I/O) module and enabling the use of an alternate control network topology, we are giving our customers a greater range of choices in their ESD and FGS applications. Cybersecurity has also been strengthened.

Enhancements
1. Easier adoption and use in FGS applications
Software components (function blocks) that define the operations and functions to be performed when smoke, heat, and/or gas is detected, an essential aspect of any FGS application, have been added to the ProSafe-RS engineering functions. Standard FGS faceplates have been added for the integrated display of smoke, heat, and gas detector information such as gas concentration level and device status. In addition, the I/O module has a new function that can reset the detector that sends smoke and heat detection signals to the ProSafe-RS system. This eliminates the need for a reset circuit to restore communications after an abnormality is detected, thus reducing both the size of the hardware and its initial cost. With these enhancements, the ProSafe-RS is easier to adopt and use in FGS applications.
2. New I/O module
Yokogawa provides an N-IO (Network-IO) I/O device with channels that can be configured by software to handle either analog or digital signals. As most safety instrumented systems rely mainly on digital I/O signals, the company has added a new I/O module to its lineup that is used for only the input or output of digital signals. This new module reduces the total cost of ownership for users.
3. Ring network topology
For the Vnet/IP®  real-time control bus, ProSafe-RS has relied on the star network topology, in which all devices are connected to a central hub. The new ProSafe-RS is also compatible with the ring topology, in which devices are connected to each other in the shape of a ring. This feature affords our customers greater flexibility when configuring their systems.
4. Improved cybersecurity
As a result of enhancements made to the ProSafe-RS engineering station’s software security functions and changes to the Windows® security settings, users can now set their systems to a higher security level. This latest ProSafe-RS release also supports a Windows function that enables the centralized management of security settings. With this feature, users can apply the same security settings to multiple monitoring and operation PCs, thus greatly improving plant security.

The target markets and applications for the ProSafe-RS include emergency shutdown systems (ESD), burner management systems (BMS), and fire and gas systems (FGS) in process industries such as oil, natural gas, petrochemicals, chemicals, pharmaceuticals, electric power, and iron and steel.

Safety certification for switches.

United Electric Controls (UE) has received SIL 2 certification on two of its most popular electromechanical switch offerings. Combined with the award-winning SIL 2-certified One Series Safety Transmitter, UE now offers process instrumentation end users with a unique range of options for high-reliability electromechanical or digital switching in general process or hazardous area functional safety applications.

"As global economies become more dynamic and volatile, industrial companies are looking for new ways to reduce risk and are increasingly demanding SIL certification on new instruments. Although our electromechanical switches are already well-known for their reliability, we have obtained SIL certification to provide an added level of assurance. Combined now with our SIL-certified One Series Safety Transmitters, we offer a broad set of options for cost-effective and reliable safety switching,” said Wil Chin, Vice President of Marketing and Business Development, United Electric Controls. 

Global safety certification leader exida has certified United Electric’s (UE’s) 100 Series and 120 Series pressure, differential pressure and temperature switches for use in a SIL 2 environment, with systematic capability at SIL 3 level. The option for SIL 3 reliability in electromechanical or digital switching provides great flexibility to optimize instrumentation around performance, safety or economic objectives.

High-reliability, high-speed switching at low cost

Switch users looking only for economical, high speed electromechanical SIL 2 level switching can specify the 100 Series for weather-proof general applications. The 100 Series provides pressure or temperature switching for process plants and OEM equipment. Its one-piece enclosure features a clamshell cover for easy wiring accessibility, with a wide variety of microswitch, sensor and process-connection options. Typical applications include heat tracing, freeze protection, processing equipment (pumps, compressors), inputs for annunciator panels and fire suppression systems.

High-reliability, high-speed switching in hazardous environments

Those needing SIL 2 level reliability temperature and pressure switching in Division 1/Zone 1 hazardous environments can consider the explosion-proof UE 120 Series electromechanical switches. The 120 Series performs critical safety, alarm and shutdown functions in oil & gas, petrochemical, and refining industries. They are also globally certified for hazardous applications in North America (cULus), Europe (ATEX, CE, IECEx), India (PESO), Russia (EAC), and other regions.

High-reliability digital switching

Those seeking the financial and operational benefits of having a complete safety instrumented system (SIS) in a single digital unit would specify UE’s One Series Safety Transmitter. One Series Safety Transmitters uniquely bundle rapid switching, safety logic solving and temperature or pressure sensing in a single housing. They are equipped with digital displays and diagnostic capabilities and shipped SIL 2 certified (SIL 3 Capable) from the factory, removing risk of implementing external relays and controls.

The newly SIL-certified electromechanical switches will be available for sale on May 1, 2017. The One Series Safety Transmitters are available immediately.

 @UEControls #PAuto  #Safety

Gas detector approved to SIL2.

Tyco Gas & Flame Detection (Tyco GFD) is pleased to announce that the DG-TT7-S H2S gas detector with Metal Oxide Semiconductor (MOS) sensor underwent stringent functional safety assessments by an external certification body and is now SIL 2 approved.

The DG-TT7-S is solid-state metal oxide semiconductor (MOS) gas detectors used mainly for the detection of hydrogen sulphide (H2S) in arid locations having air present or in locations with continuous H2S background. The sensor specifies a wider continuous operating temperature range than the standard electrochemical sensors up to +65 °C.

The device supports HART 7 protocol option for full configuration and diagnostics over non-proprietary interface.

The MultiTox DG-TT7-S features on board relays, plug and play sensors and a high visible display that changes colour depending on the status mode.

 @TycoGFD #Pauto #SIL

Machinery protection system with SIL 2 Certification.

With SIL 2 certification, the AMS 6500 Machinery Health™ Monitor improves reliability in safety instrumented system environments including power and nuclear plants and critical refining assets

Emerson’s AMS 6500 Machinery Health Monitor is now certified for Safety Integrity Level (SIL) 2, providing users greater confidence against asset and process failures. Common examples of process applications where SIL 2 advanced safety integrities are needed are steam and gas turbines in power plants and critical refinery and nuclear industry assets.

The AMS 6500’s certification gives users added assurance that it will reliably deliver the appropriate insight into the health of critical assets. Whether organisations need SIL certified equipment to meet company guidelines or to comply with legal requirements, SIL ratings help evaluate whether a specific technology meets the selected risk tolerance for industrial applications.

“More and more organisations are finding they need SIL 2 certification to meet international standards and machine directives requiring certain SIL ratings,” said Björn Müller, product manager for sensors and systems, Emerson Automation Solutions. “SIL certification is one more way we can help customers achieve compliance while demonstrating our commitment to risk reduction.”

For critical mechanical equipment, the AMS 6500 provides predictive intelligence and protection capabilities, helping organisations achieve Operational Certainty through improved reliability and safety.

 #PAuto @EMR_Automation #Safety @HHC_Lewis  @Emerson_News

Safety certification.

Yokogawa has received TÜV Rheinland certification for Functional Safety Management (FSM) IEC 61511-1:2003 SIS Integration Phase 4 (Design and Engineering), FSM 159 (pdf).

The scope of certification covers integration of Safety Instrumented Systems (SIS) Logic Solver in the process industry up to and including Safety Integrity Level 3 (SIL3). The scope of activities includes SIS design, configuration, application programming, assembly and test, as well as safety loop calculations. This FSM certification uses IEC 611511 as the basic standard as well as relevant clauses of the IEC 61508:2010 standard.

When consumers or manufacturers see a TÜV Rheinland certification mark, they can be assured that they are buying a safe product that has been investigated to stringent safety requirements by an accredited third party and is supported by regular surveillance audits and factory inspections.

“This is an exciting achievement for Yokogawa and our customers,” said Sriram Srinivasan, Director of Engineering, Yokogawa Corporation of America. “The TUV Rheinland certification provides customers assurance that the FSM system we deliver is fully compliant with standards. We are now certified on the three critical Ps in delivering FSM systems – People, Process, and Products.”

The systematic capability of the Yokogawa process is certified to SIL3. These systematic capabilities and procedures ensure that the potential for systematic errors are minimized in the projects executed for customers. “Our SIS engineers, ProSafe SIS logic solver and pressure, temperature, flow (Coriolis), oxygen sensor/ transmitters are all SIL 2/3 certified. Our FSM design and engineering process, our people, and our products are all certified by TÜV, so this delivers a solution that is all certified by a single independent auditor and ensures the certification approach for each component is consistent,” said Srinivasan.

Functional safety is a core focus and a core competency at Yokogawa. They deliver consistent performance. SIS products and processes are standardized across the globe, and SIS engineers are certified to an equivalent competency level to deliver safety instrumented systems that comply with IEC 611511 and IEC 611508 standards.

@YokogawaIA #PAuto #SIL

SIL 1 safe protection for machinery.

CSI 6500 Machinery Health™ Monitor now offers a SIL 1 certified protection system for improving reliability in SIS environments

Operating safety-critical equipment without reliable machinery health insight to issues such as missed or false trips and alarms can keep operations unreliable and increase risk. Emerson Process Management’s CSI 6500 Machinery Health Monitor now has an IEC 61508:2010, Safety Integration Level (SIL) certification, Level 1, making it suitable for use in delivering reliable protection monitoring in such environments as steam and gas turbines in power plants, critical refinery assets, nuclear industry critical assets, and other safety-critical applications.

“While building safety products, it is important to ensure the availability of the whole safety system to keep it in operation for many years,” said Thomas Wewers, director of technology for Emerson’s reliability solutions. “Emerson’s commitment to safety has always been a top priority and as process systems become more and more intricate, built-in safety features are even more important. SIL certification is one more way of showing our customers that we are committed to helping them reduce risk.”

The CSI 6500 provides insight into the health of critical assets with both protection and prediction in a single chassis. The CSI 6500 integrates seamlessly into an overall Safety Instrumented System (SIS), such as Emerson’s DeltaV SIS™, to provide operators information in a format that they are used to seeing on a standard distributed control graphics screen.

@EmersonProcess #PAuto #MachineHealth

Safety integrity level for gas detectors.

The MX 43 controller awarded SIL 1 certification.

Oldham believes that no gas detection controller should be designed that does not take functional safety standards into consideration.Although there is no legal requirement that gas detection systems to be certified to or above a SIL 1 performance level (Safety Integrity Level - according to IEC/EN 61508 and EN 50402 functional safety standards), the fact remains that these systems are life safety devices.

Because of their unwavering insistence on the safety and reliability of our detection controllers, and the broad range of applications in which they are used, we adhere to the strictest functional safety standards. Whether the application presents an elevated risk of explosion and serious consequences to employee safety, or involves toxic gas detection in high risk areas such as water treatment facilities, Oldham guarantees the one of the most effective and safest solutions for your gas detection requirements.

Safe gas detection!

Oldham believes that no gas detection controller should be designed that does not take functional safety standards into consideration.

Although there is no legal requirement that gas detection systems to be certified to or above a SIL 1 performance level (Safety Integrity Level - according to IEC/EN 61508 and EN 50402 functional safety standards), the fact remains that these systems are life safety devices.

"Because of our unwavering insistence on the safety and reliability of our detection controllers, and the broad range of applications in which they are used, we adhere to the strictest functional safety standards." said a spokesman. Whether the application presents an elevated risk of explosion and serious consequences to employee safety, or involves toxic gas detection in high risk areas such as water treatment facilities, Oldham guarantees the one of the most effective and safest solutions for your gas detection requirements.