Safety Instrumented Systems life-cycle examined!

The International Society of Automation (ISA) has published a new book that covers the entire life-cycle of safety instrumented systems (SIS)—including specification, design, analysis, programming, installation, maintenance, and change management.

Safety Instrumented Systems: A Life-Cycle Approach by Paul Gruhn*, PE, CFSE, and Simon Lucchini, CFSE, MIEAust CPEng, leverages the performance and documentation requirements defined in the ISA/IEC 61511 functional process safety standard along with the authors’ nearly 80 years of safety system experience, expertise and insights.

“The world of safety instrumented systems is complex; technology and knowledge continue to grow and evolve,” says Gruhn, Global Functional Safety Consultant at aeSolutions who developed the first commercial control and safety system modeling software more than 25 years ago. “This new book provides the ‘must-know’ material on the entire safety instrumented system lifecycle that practitioners need. And it does so in an easy-to-read, conversational style and in a highly condensed format.”

In addition to explaining the significance and value of the ISA/IEC 61511 standard in improving functional process safety, the book, Gruhn emphasizes, provides important practical guidance and real-world case studies and experiences.

“To properly design, install, commission and operate a safety system, you have to align the performance requirements of the standard with how process plants operate and how projects are executed,” points out Lucchini, Chief Controls Specialist and Fellow in Safety Systems at Fluor Canada and the Safety Systems Committee chair of ISA’s Safety & Security Division. “Safety needs to be integrated into the design rather than ‘bolted on’ at some late stage of the project. This book helps guide functional safety engineers and others involved in process industry safety to the right decisions about safety systems at the right time.”

* Paul Gruhn is President-Elect of the ISA who will take office in January 2019 for a one year period. See our story - The Results are in (October 2017) 

#PAuto #Safety #ISAuto 

SIS inspections & tests.

The International Society of Automation (ISA) and its promotional partner, Beamex, Inc., will co-host a free webinar 31 January 2018 on documenting safety instrumented system (SIS) inspections and tests.

Paul Gruhn, President Elect/Secretary ISA 2018

The webinar, which will be held from 12 p.m. to 1:30 p.m., Eastern Standard Time, will feature three automation experts: Paul Gruhn, Global Functional Safety Consultant at aeSolutions; Ned Espy, Technical Director at Beamex; and Roy Tomalino, Calibration Engineer at Beamex.

Calibration professionals are very often asked to perform inspections on instrumentation. This webinar will review the best practices of inspecting, testing and documenting a SIS, and will explore how to apply these practices in the field to not only SIS, but also to simpler instruments, such as valves.

As Tomalino, the Beamex engineer explains, “Safety instrumented systems are a high priority and get a significant amount of visibility from inside and outside organizations. Documenting results is often a daunting challenge that we tend to shy away from, but it doesn’t need to be. Performing SIS inspections and documenting them can be a minimal additional effort. Join the webinar to watch us demystify this process. We also invite you to share your hot issues, live on the webinar. We will answer and discuss as much as possible in the time allotted. This isn’t just about us, it’s about collaborating with you and sharing. Even as a technical instructor, I learn something new every time I present in a webinar or teach a class. Join us and add to the knowledge base.”

“Today’s modern plants require optimal SIS performance in order to safeguard personnel, the environment and production assets, and at the same time, maximize uptime and minimize operational disruptions,” says Jennifer Infantino Halsey, ISA’s Director of Marketing & Communications. “Therefore, it’s essential that SIS inspection, testing, and documentation best practices be followed. ISA is pleased to join with its Beamex partner in offering this important informational webinar.”

The Speakers Paul Gruhn is a Global Functional Safety Consultant at aeSolutions in Houston, Texas. Gruhn has specialized in safety systems for 30 years. He is an ISA Life Fellow, co-chair of the ISA 84 standards committee, the developer and instructor of ISA courses on SIS, and the primary author of the ISA book on the subject. Gruhn developed the first commercial control and safety system modeling software more than 25 years ago. He received a bachelor of science degree in mechanical engineering from IIT in Chicago, IL. Gruhn is a professional engineer (P.E.) licensed in Texas, a certified functional safety expert (CFSE), a member of the control system engineer P.E. exam team, and an ISA 84 expert. He is the 2018 ISA President-elect/Secretary. Ned Espy, Technical Director at Beamex, possesses more than 27 years of direct field experience in instrumentation measurement applications. He has been concentrating on calibration management at Beamex for more than 20 years. Espy is a recognized expert in developing best practices for calibration, with a particular focus on temperature, pressure and multi-variable instruments. A consistent editorial contributor to leading industry publications, Espy has received significant acclaim within the automation industry. Each day, Espy teaches calibration best practices and provides technical support to end users and to the Beamex sales team in North America. Roy Tomalino, a Beamex Engineer, possesses more than 16 years of technical training experience. He has served as a trainer, certified developer and technical advisor on four continents to people from more than 40 countries. Tomalino was a key player at Honeywell at its Fort Collins, Colorado office, where he supported the “DocuMint” Calibration Management Software and numerous calibrators as a trainer, certified developer and technical advisor. He also served as a worldwide trainer at Hewlett Packard. Today, Tomalino serves as a Beamex “evangelist,” supporting customers and the Beamex team in North America.

Click button to register!

The webinar will take place 31 January 2018, from 12 p.m. to 1:30 p.m., Eastern Standard Time.

#PAuto #ISAuto @BeamexGlobal 

Safety instrumented system to be launched next week!

Yokogawa's ProSafe(R)-RS R3.02.20 is to be launched in a few days (2014). This enhanced version of the ProSafe-RS safety instrumented system (SIS) offers improved connectivity with the ProSafe-SLS SIS, enabling the status of both systems to be monitored on-screen by operators of the CENTUM® VP integrated production control system. In addition, R3.02.20 offers enhanced support of widely used open communication protocols, improving connectivity with other companies' SCADA (Supervisory Control & Data Acquisition) software.

Development background
In the oil, natural gas, petrochemical, iron & steel, and other energy and basic materials industries, plant safety is a growing concern. There is thus a rising demand for SISs that can help to prevent accidents by detecting abnormal conditions and initiating actions such as an emergency plant shutdown. Yokogawa provides two different SISs, the programmable ProSafe-RS and the solid-state ProSafe(R)-SLS, and customers select which systems to utilise based on their facilities' requirements. For customers who use both SIS systems, there is need for a solution that will enable the status of both these systems to be monitored in an integrated manner.

Overview of enhancements
1. Integrated monitoring of systems
With the ProSafe-SLS information gathering capability on ProSafe-RS SIS, operators can now monitor the status of a ProSafe-SLS SIS from a CENTUM VP window. If a problem occurs anywhere in a plant, the sequence-of-event (SOE) data from both SISs will be displayed on an integrated screen at the operator terminals. Operators and maintenance engineers can then use this data to quickly identify and analyse the problem cause.

2. Communication protocol support for upstream applications
In oil and gas wellhead and pipeline applications, cost performance and space saving are key considerations. To satisfy these needs, ProSafe-RS is equipped with both safety and process control functions. The SCADA systems at such sites often rely on Distributed Network Protocol 3 (DNP3) for narrowband wireless and satellite upstream communications because this open protocol supports the temporary storage of data when there is a disruption in network communications. Support of DNP3 in the ProSafe-RS R3.02.20 controller enables customers to easily replace and expand their systems in the field while continuing to use their existing SCADA infrastructure. This saves time and reduces costs.

Valve controller for safety instrumented systems

Intelligent automatic partial stroke valve testing provides improved safety and reliability

Emerson’s new FIELDVUE™ DVC6200 SIS digital valve controller responds to safety demands, and features partial stroke and position monitoring capabilities for the final control element in a safety instrumented system (SIS). Intelligent automatic partial stroke valve testing provides improved safety and reliability versus traditional pneumatic and jammer partial stroke methods.

Meeting plant safety and reliability targets is easier using the DVC6200 SIS, which combines the field-proven linkage-less, non-contact feedback design of the DVC6200 and DVC2000 platforms with the safety demand and automatic partial stroke testing capability of the DVC6000 SIS. The DVC6200 SIS has been evaluated to the latest version of IEC 61508 (2010) and is certified as a SIL 3 capable device for both 4 or 20mA and 0 or 24Vdc power settings.

An integral position transmitter is available with the DVC6200 SIS, and is capable of reading valve position even upon loss of power to the digital valve controller. The position monitoring safety function has been evaluated independently from the digital valve controller safety function and is SIL 2 capable.

Partial stroke valve testing can be used in service to safely increase the period of time between proof-testing the final control element. Additionally, the DVC6200 SIS confirms solenoid operation and captures useful diagnostic data during a trip event.

When integrated with Emerson’s DeltaV™ SIS logic solver, the native interface provides users increased availability, while at the same time removing complexity from their safety systems. DeltaV SIS provides out of the box tools that allow direct access to the DVC6200 SIS diagnostics and partial stroke data, and the ability to set-up and run the partial stroke tests automatically.

Enhanced safety instrumented systems!

The enhanced version of ProSafe-RS safety instrumented system ensures safe operation of plants and upstream oil and natural gas facilities

Yokogawa Electric Corporation has released an enhanced version of its ProSafe-RS safety instrumented system. This new version, ProSafe-RS R3.02.00, features input/output modules that will operate reliably in the high-temperature conditions typically encountered in desert locations. Support of an open communications protocol has also been added, enhancing the system’s compatibility with other vendors’ distributed control systems (DCS).

Development background
In the oil, natural gas, petrochemical, iron & steel, and other energy and basic materials industries, it is becoming increasingly important to ensure the safety of plant operations to prevent accidents, protect the environment, and be good corporate citizens. Accordingly, there is a growing demand for safety instrumented systems that can detect abnormal conditions and safely initiate emergency shutdowns.

Control devices and safety instrumentation systems are often installed outdoors for monitoring oil and gas wells and pipelines. As many of these facilities are in desert locations, they must be able to operate in high-temperature conditions.

In addition, plant operators who replace their safety instrumentation systems to improve productivity and safety need to maintain compatibility with their existing distributed control systems.

To satisfy these needs for high-temperature resistance and inter-system compatibility, Yokogawa has developed this enhanced version of the ProSafe-RS safety instrumented system.

Overview of enhancements
1. High-temperature resistant input/output modules
High-temperature resistant digital and analogue input/output modules have been developed. Previously, input/output modules had to be spaced far apart to prevent the accumulation of heat. While mounted closely together, the new modules can operate at ambient temperatures of up to 70°C (158°F). This reduces the system footprint.

2. Modbus/TCP protocol support
Safety instrumented systemsand distributed control systems are not always replaced at the same time. Therefore, ProSafe-RS has been enhanced by adding support for Ethernet-based Modbus/TCP communications with other systems. Modbus is an industrial communications protocol developed by the US company Modicon (now owned by Schneider Electric). This facilitates the flexible connection of the ProSafe-RS system with distributed control systems from other vendors, allowing Yokogawa’s customers a greater range of choice.

Takashi Nishijima, a Director and Senior Vice President, and Head of Yokogawa’s Industrial Automation Platform Business Headquarters, comments: "The latest version of ProSafe-RS was developed to achieve safety excellence at our customers’ production sites, which is one of the aims of our VigilantPlant range of solutions . Safety is the most important consideration in plant operations. With this new version, ProSafe-RS is now capable of ensuring that our customers’ systems work precisely and safely under high-temperature conditions. The tighter connection not only with CENTUM systems but also other vendors’ systems makes it easier for companies to adopt our highly reliable safety instrumented system. We will continue our efforts to develop products that support our customers’ plant operations."

Major target markets and applications
Major target markets and applications include emergency plant shutdown, fire prevention and firefighting in the oil, natural gas, petrochemical, and other process industries

Multiplexer gains SIL3 rating!

The MTL4850 Hart Multiplexer gains SIL3 rating for functional-safety related loops

The SIL3 rated MTL4850 Hart Multiplexer is now available. MTL is known worldwide as an intrinsic safety interface specialist, and now takes the lead in functional safety components by introducing the SIL3 rated MTL4850 Hart Multiplexer for connection to instrument loops performing safety functions up to and including Safety Integrity Level SIL3.

This multiplexer is designed to ensure that there is no effect on the analogue loops to which it is connected; multiple concurrent faults in the components that couple the MTL4850 to the analogue loops would have to be present before the isolation would be compromised. The MTL4850 HART multiplexer does not itself implement a safety function but may be applied alongside measurement and control equipment that is providing a safety function.

Unique design features make it suitable for use in applications where the 4/20mA instrument loops, to which it is connected, are implementing safety functions up to SIL3 and the techniques used mean that systematic faults can be prevented.

The multiplexer provides a common bridge to access HART information for the signal channels that are connected to it, This is particularly important when the multiplexer is associated with signal loops that are feeding a safety shutdown system.

MTL continues to increase its functional safety product portfolio which demonstrates its commitment to comply with IEC61508:2010. Moreover, this certification as a Functional Safety Management Company demonstrates that MTL has processes and competence to design and market products according to the international standard. Thus the customer may have the confidence to use MTL’s products in Safety Instrumented Systems.

Indonesian DCS & SIS orders

DCS and SIS orders placed by Indonesia's CAP Group

Yokogawa Electric Corporation has announced that its subsidiary, PT. Yokogawa Indonesia, has received an order from PT. Chandra Asri Petrochemical Tbk. (CAP) to replace the legacy distributed control system (DCS) and safety instrumented system (SIS) at the company's ethylene and polyethylene plant in Cilegon, which is in western Java's Banten Province.

This CAP facility is Indonesia's premier petrochemical plant, incorporating world-class, state-of-the-art technology and supporting facilities. The plant's naphtha cracker produces high-quality ethylene, propylene, crude C4 and pyrolysis gasoline (Py-gas) for the Indonesian as well as regional export markets. These are basic petrochemical products obtained from the distillation of crude oil. Crude C4 includes butane and butylene that have four carbon atoms per molecule.

Yokogawa Indonesia has also received an order from the CAP subsidiary PT Styrindo Mono Indonesia (SMI) to replace the legacy DCS at the company's styrene monomer plant, which is about 40 km from the CAP plant and has an annual output of 340,000 MT.

For these projects, Yokogawa Indonesia will provide the latest CENTUM(R) VP DCS and ProSafe-RS SIS along with engineering, installation, commissioning, and engineering and operator training. These projects are expected to take 10 months from start to finish.

Key factors in the CAP Group's selection of Yokogawa for these replacement projects were the high reliability and global track record of Yokogawa's CENTUM VP and ProSafe-RS platforms, the close project support made possible by global co-operation between Yokogawa Indonesia and Yokogawa Engineering Asia Pte. Ltd., which is responsible for the Yokogawa Group's operations in Asia, and the company's global maintenance and service network.

Ichsan Gafar, a director at Yokogawa Indonesia, says: "I think that the customer assessed and scored Yokogawa as the best long-term partner of the CAP Group, considering the strength of our products in terms of reliability and expandability, the operability of an integrated DCS and SIS solution under the Yokogawa brand, and our local engineering, project execution, and after-sales support capabilities. Through our implementation of these DCS and SIS projects for CAP and SMI, we will strengthen our relationship with the CAP Group. We aim to win contracts for their other projects as well and to expand our share of the Indonesian industrial automation market."

Automated independent backup system

SIS-TECH now has the DIAMOND-SIS automated independent backup (AIB), a low-cost, standalone safety instrumented system (SIS) that backs up current process control trip logic and meets the requirements of IEC 61511. The system includes an IEC 61508 logic solver that is functionally independent from the process control system, supplements existing logic, and meets all appropriate safety standards.

This system provides high integrity and process reliability. It is available in single, dual, and triplicated channel configurations with on-line diagnostics, testing, and maintenance capabilities. The single and dual channel systems are acceptable for SIL 2, while the triplicated channel system is certified by Factory Mutual to SIL 3. This means that it can meet the fault tolerance and PFavg requirements of any application.

With its 5A output rating, the system can de-energize multiple final elements including motor control circuits and/or solenoid operated valves. Local or remote manual reset ensures controlled process re-start after shutdown.

It is particularly useful with legacy control systems that do not meet current SIS standards. Typically, during the early days of digital control, users implemented safety logic within their process control systems. Today, they do not want to impose SIS requirements or management restrictions within the existing systems.

Instead, they need an independent backup safety logic system that connects easily to existing plant equipment, meets all safety standards and requirements, and requires no reprogramming of process logic since it fulfills all of those requirements.

Easier to install and maintain than a Safety PLC
A single channel DIAMOND-SIS AIB system includes a pre-mounted and wired DIN-rail signal isolator, a Model 340 logic solver, a fuse block, and five terminals ready to accept existing wiring. All components are rated for -30 to 75 degrees C and Class I Div II operation, and meet the mechanical integrity requirements of IEC 61511.

The system can typically be mounted in an existing DCS marshalling cabinet, and the user wires the logic solver contacts in series with the DCS contacts. The logic solver then independently backs up the trip functionality of the DCS.

Each DIAMOND-SIS logic solver module can accept virtually any analog input. Its two field adjustable trip points allow the process to be shut down on high and/or low process variables, or to detect an out of range signal fault. The number of inputs and the voting architecture—such as 1oo1, 1oo2, 2oo2 or 2oo3—can be adjusted to meet performance requirements. The process shut-down signal from the logic solver can be sent to both the DCS, and directly to a shut-down device such as a relay or solenoid.

The installation does not require any reprogramming of the existing DCS. In addition, the installation cost of a system is 80% less than that of an equivalent Safety PLC with the same number of loops. Maintenance costs are also greatly reduced as it’s not necessary to purchase, implement and renew programming software.

The Safety Requirements Specification, including Safety Integrity Level (SIL) verification documentation, can be supplied as an option. This makes the DIAMOND-SIS AIB the perfect packaged solution to address low I/O SIS needs, and the low cost alternative to safety PLCs.