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Engineering Practice

Safety-Instrumented Systems:
Focus on Measurement Diagnostics
WirelessHART and other new approaches
help operators to achieve the needed safety
at the lowest lifecycle cost !

Terminal voltage, V
Stephen Brown Mark Menezes
DuPont Fluoroproducts Emerson Process Management

his article provides guidance now be assigned a probability of “0.1

T to the designer and operator of


a safety-instrumented system
(SIS), with an emphasis on con-
ducting measurements. The use of
best practices to ensure the strength
events per year.” That article guided
users through the process of finding
these numbers. This was found to be
a particular challenge for field devices
such as sensors. What is the risk that a
4mA
Output current, mA

FIGURE 1. The transmitter characterizes


the “normal” relationship between cur-
20mA

of the overall system design, and the given transmitter might falsely report rent and voltage at commissioning, then
alerts the user to changes during opera-
use of instrument diversity to combat a safe condition? While suppliers can tion, which might indicate a problem
common causes of failure, are covered provide safety statistics that are “cer-
briefly. Greater detail are provided on tified” by third parties, those data are
the use of new technologies — in par- typically derived from white papers or orifice plate, use a vortex flowme-
ticular, new smart-transmitter diag- laboratory analysis. Is the actual risk ter. Choose a vortex design that is
nostics and digital protocols, including greater in a “real world” installation? immune to the common cause of
wireless options. Might the risk be significantly differ- plugging
ent for two identical devices that are • Diagnostics — Select a transmit-
Background in different installations? How can the ter that can detect that its lines are
Best practice design of SIS has evolved user quantify these “installed” risks? plugged
over the past decade, prompted by the The focus of a follow-up article by
widespread adoption of the ANSI/ the authors [2] was on strategies for Best practices
ISA-S84.01-2004 Standard, which is minimizing, rather than quantify- To maximize the strength of an over-
itself based on IEC 61511. In their ing, identified risks. Since users com- all SIS design users should employ
first article on this subject [1], the monly employ redundant sensors in the same best practices that apply to
authors described how the new stan- critical applications, special atten- any process measurement applica-
dard encourages a user to change from tion was paid to identifying “common tion, whether used for safety or for
purely qualitative risk assessment to causes,”which can impact both sensors basic process control. Note that best
quantitative risk analysis. One benefit in a redundant system. For example, if practices tend to be specific to a given
of the qualitative approach is that it a user has identified that impulse line technology, and evolve over time with
is prescriptive and hence simpler to plugging in a given installation might technological advances. Some exam-
apply — the user is told what to do to cause the pressure transmitter to ples of best practices with particular
achieve safety. falsely report a safe condition, rather relevance to safety applications in-
One potential downside is that the than trying to quantify that risk, a clude ensuring that:
qualitative approach is designed to better approach is to make the risk so • The measurement uncertainty is
produce conservative results, which small that it no longer has a material smaller than the safety margin. For
can result in over-design. The quan- impact. The user was advised to em- example, if a process is operated
titative approach is more flexible — ploy a strategy that aimed to improve within 5% of where it becomes dan-
the user can use whatever approach strength, diversity and diagnostics: gerous, the measurement must be
minimizes lifecycle cost while still • Strength — Change the installation much better than ±5%. This sounds
achieving the desired risk reduction. by shortening and widening the im- obvious, but is often not the case.
The designer must substitute quanti- pulse lines so they don’t plug While tools and methodologies exist
tative data for qualitative descriptors; • Diversity — Rather than using a [3] to quantify measurement uncer-
for example, a dangerous event previ- second (redundant) differential tainty, many users do not routinely
ously described as “very likely” would pressure (dP) transmitter on a given employ these
58 CHEMICAL ENGINEERING WWW.CHE.COM APRIL 2013
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this probability of failure on demand


(PFD) is 0.05, which means that if
20 transmitters are called on to shut
the dangerous process down, one
will fail to do so (Note: There are no
units for PFD because it represents
the probability that a safety system
or component will fail to respond to
a demand)
• The density of the fluid in the ves-
sel will change, so the output of the
transmitter does not reflect the true
level. It may be reasonable to as-
sume a PFD of 0.04 for this risk

PFDTotal = PFDTransmitter + PFDDensity=


0.05 + 0. 04 = 0.09
Making the device redundant:
FIGURE 2. The Statistical Process Monitoring (SPM) screen shows that while the
process’ mean has not changed, its high frequency variability has increased PFDTotal = (PFDTransmitter)2 +
PFDDensity
=(0.05)2 + 0.04 ≈ 0.04
• The thermowell is properly designed For example, a radar level meter
for the application. Poor thermowell used for drum level control must This is of course a simplified calcula-
design has been cited in the 1995 compensate for changing density of tion, but it should be apparent that
failure of the Monju fast-breeder the steam in the boiler drum continuing to add redundancy — for
reactor, which caused a spill of ra- • Proper materials are selected. This is instance, making the transmitter tri-
dioactive sodium [4]. Although no key to avoid effects such as hydro- ply redundant — will yield little bene-
radiation was leaked to the environ- gen permeation, or stress corrosion fit, since the common cause of density
ment, the reactor was not restarted cracking in environments with high variation will continue to dominate
until September 2010 — 15 years vibration or pressure cycling total system risk. Instead, the user
after the incident. New standards, To the greatest extent possible, the should install a different (diverse)
such as ASME PTC 19.3-2010, sig- user should maximize the consistency technology that is not affected by den-
nificantly improve the reliability of of devices and practices between the sity variation.
wake-frequency calculations and measurements that are used for the Rather than trying to find a best
minimize the risk of thermowell safety system and the basic control practice to apply to a given technology,
failure due to flow-induced vibration system. While the use of a new, un- the user should consult a technology
and transient effects familiar device or practice solely for selection guide, widely available from
• The measurement is fast enough to safety applications may yield some technical societies such as the Inter-
detect the hazard. Speed of measure- benefit in theory, in practice the user national Soc. of Automation (ISA). A
ment response is affected by the is more likely to make an error dur- truly objective guide avoids character-
device, the installation and applica- ing design or maintenance, due to lack izing any given technology as “better
tion conditions. Again, few users go of familiarity [6]. In addition, failure or worse,” but, instead it identifies
through the effort to quantify re- statistics gathered from basic process relative strengths and weaknesses of
sponse time in a given application control installations can be leveraged different technologies. For example,
except when response time is known for safety system design if those in- a level selection guide [7] should ex-
to be critical (for instance, for com- stallations are consistent. plain that radar-based level-measure-
pressor anti-surge [5]). Similar ef- ment devices — both contacting and
fects are seen with temperature Employ diversity non-contacting — will be immune to
measurements, although there the Common causes of failure usually variation in fluid density.
sensor and thermowell dominate dominate safety risk in installa- Such a description is not to suggest
the overall response time tions with redundant transmitters. that radar is necessarily “better” than
• Measure mass flow of gas and steam. Consider the case of a pressure or a level-monitoring device based on dif-
Use a multivariable flowmeter that displacement-style level transmitter ferential pressure (dP). It just suggests
compensates for changing density, used to ensure that a vessel does not that radar is resistant to the identi-
or measure mass flow directly using overflow. For these installations there fied common cause, and thus should
a Coriolis flowmeter are two main risks: be suitable as a backup to the chosen
• In a top-down level measurement, • The transmitter electronics will fail primary technology. Similarly, an ad-
significant changes in the vapor dangerously and provide the wrong vantage of dP-level measurement over
space are dynamically compensated. output. Consider a case in which radar-based options is that the former
CHEMICAL ENGINEERING WWW.CHE.COM APRIL 2013 59
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Engineering Practice

can ignore the effects of vessel inter-


nals that reduce the signal-to-noise
ratio. For instance, reflections from
agitators or baffles can increase noise
and foam, or vapor can absorb radar
energy and reduce signal strength. In
an installation that relies on radar as
the primary measurement technique,
if the user identifies internal vessel
effects as a significant common cause
risk, then dP-level monitoring devices
would be a suitable backup option.
Complementary strengths and
weaknesses can be found in other mea-
surement applications. For instance,
in temperature measurement, RTDs
are accurate and stable, while ther-
mocouples are physically robust. In a FIGURE 3. After an upset or near-miss, the user can review the diagnostic logs of
waste-gas flow application, a Coriolis attached transmitters to see if anything unusual occurred just prior to the upset. In
this case, high variability was observed
flowmeter provides higher turndown
and is less affected by changing gas
composition, while a dP-flowmeter is updating. The safety benefit of these in voltage of the thermocouple, or
more stable in low gas pressures and internal diagnostics are accounted for changes in resistance of the RTD.
introduces less permanent pressure in the Failure Modes and Effects Diag- This means that a transmitter con-
loss. These guidelines evolve over time. nostic Analysis (FMEDA) safety data, nected to a thermocouple has unused
Modern Coriolis meters can be sized to which are provided by the supplier, resistance circuitry, which it can use
provide acceptable accuracy at lower and explains why newer transmitters to characterize “normal” resistance of
pressure drops compared to older de- provide superior safety statistics com- the thermocouple and associated wir-
signs, and modern dP-flowmeters now pared to older devices. ing, and alert the user to changes that
offer higher overall turndown. For this Some diagnostics require user ac- indicate temperature-measurement
reason, the user should use the most tivation. For example, diagnostics errors and impending failure. Again,
up-to-date technology selection guide. are available to detect power supply this improves safety, and can extend
problems. A loop might be unable to the schedule for temperature-sensor
Diagnostics improve safety reach an output higher than 18 mA proof testing.
The most direct way for a user to ob- because the power supply is browning The most advanced smart transmit-
tain a “process diagnostic” is to add a out or cannot keep up with load from ters contain microprocessors that read
measurement, or upgrade a switch to a all the devices in the loop. Or, water the sensor 20 times or more per sec-
transmitter. While a switch can freeze might have leaked into the housing, ond. While the logic solver or control
in position, a transmitter that fails in causing an output shift. As shown in system can only handle an “average”
position can be detected by an alert Figure 1, newer transmitters charac- signal two or three times per second,
operator. Even where the new trans- terize the relationship between cur- the high-speed, unfiltered signal is
mitter is not connected to the safety rent draw and transmitter terminal useful for characterizing high-fre-
system, a deviation between the new voltage at commissioning, and alert quency process variability within that
transmitter and the existing safety the user during subsequent operation average.
system transmitter can alert the user to changes that would indicate a prob- The meaning of a given increase or
to a problem. Conversely, agreement lem. As with internal diagnostics, the decrease in variability depends upon
between the two transmitters can help safety benefit of power diagnostics are the process. For a pressure transmit-
the user to justify extending the proof accounted for in the supplier’s safety ter, a decrease in variability could in-
test interval. data, with further improved trans- dicate plugging of the sensing line or
Internal transmitter diagnostics be- mitter safety statistics. An additional coating of the diaphragm seal. In a
came available with the earliest smart benefit of this diagnostic is that the flow application, an increase in vari-
transmitters, and have become more user can eliminate the need for peri- ability without a corresponding in-
sophisticated over time [8]. They can odic manual proof testing of the loop’s crease in mean — shown in Figure 2
detect internal faults — for example, high- and low-alarm limits. — could signal that the liquid flow is
the microprocessor can discover that Temperature transmitters are con- becoming entrained with gas, or that
its non-volatile memory has become figurable to accept either thermocou- the steam flow is becoming “wet” with
corrupted by an electrical or magnetic ple or resistance temperature detec- liquid water. Either can cause mea-
disturbance, or that an internal to- tion (RTD) inputs. The transmitter surement error, and also damage to
talizer or cyclic counter has stopped obtains temperature from changes mechanical components. In most tem-
60 CHEMICAL ENGINEERING WWW.CHE.COM APRIL 2013
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is a “failed” status, which means the


transmitter output can no longer be
trusted, even if it remains onscale be-
tween 4 and 20 mA. The device that
detects this type of failure immedi-
ately provides an offscale output —
higher than 20 mA or lower than 4
mA, configurable by the user— to ad-
vise the logic solver that the process is
operating dangerously.
Properly implemented, measure-
ment diagnostics provide additional
benefits. First, the user can be alerted
to lower levels of severity preceding
“failed.” A “maintenance required”
status informs the user that the mea-
surement, while probably correct now,
FIGURE 4. With a risk of line plugging, the sensor dominates system risk at 78% of will eventually become invalid — and
the total PFD, and limits the system to a risk reduction factor of 868 (SIL-2) cause a failure — unless the user per-
forms some remedial action. Many fail-
ures develop gradually, so the user can
perature and level applications, the the diagnostic will detect it. Values are be informed of an “impulse line start-
rate of change is limited by the physics derived from operating experience, in ing to plug,” a “thermowell starting to
of the process. A large, sudden change the same or similar applications. Until coat,” or a “power supply starting to
is not physically possible, and usually the user has gained experience with a brown out.” The “water in terminals”
reflects some external influence like given diagnostic, the user should op- diagnostic signals small amounts of
electrical noise. Rather than damping erate the diagnostic in “open loop”, condensate that cause a measurement
the signal, which slows response time so that a diagnostic alert causes the shift, but if ignored will eventually
to a genuine process upset, the smart operator to investigate further. That — in weeks or months — cause corro-
transmitter will ignore the spike or means that the diagnostic coverage sion through the terminals and device
dropout for a scan or two, holding the must be de-rated to account for opera- failure. A downward trending signal-
last value for the logic solver. tor response time. to-noise ratio for a radar level meter
It’s not always obvious in advance Once the user gains confidence that indicates that the antenna of the
how a change in variability should be the diagnostic does not cause false meter is gradually becoming coated
interpreted. In practice, the user lets alarms, the diagnostic can be turned by condensing fluids in the process.
the diagnostics “learn” the process. If “closed loop”, so that the transmitter If ignored, the signal will eventually
the process unit is upset — which may output goes to the failsafe position become unusable, and the transmitter
or may not engage the safety system when the condition is detected. Even will report a “failed” condition. The di-
— maintenance can later review the then, with redundant transmitters a agnostic allows the user to ignore the
date-and-time stamped historical logs single alarm should not cause shut- antenna until and unless alerted to
(essentially, the transmitter’s non-vol- down, but should alert the operator the need for cleaning. This predictive
atile “black box”) to see if any of the to investigate further. Figure 4 shows maintenance has dual benefits — it
transmitters connected to the unit had a safety analysis for a transmitter in eliminates routine inspections for re-
observed a significant change in vari- an application with a risk of line plug- duced maintenance cost, and prevents
ability prior to the upset. As shown ging. The sensor contributes 78% of future failures for higher uptime.
in Figure 3, review of the log might the probability of failure on demand Failure diagnostics force a poten-
reveal that several minutes prior to (PFD), limiting risk reduction fac- tially dangerous process to shut down
the furnace flame blowout, pressure tor (RRF) to 868. Figure 5 shows the and so are valuable by themselves.
variability increased to “x%”. Process same analysis if the user implements Predictive maintenance diagnostics
engineering would confirm that this a plugged-line detection diagnostic are most useful when promptly and
correlation makes sense — and is not and takes credit for 70% coverage. clearly communicated to maintenance
just a coincidence — so the “furnace RRF improves to 2077. Implementa- personnel, and logged in a historical
pressure variability greater than x%” tion of the diagnostic therefore signifi- record. This requires enabling technol-
warning could be used to prevent fu- cantly improves safety – from Safety ogies in addition to the device diagnos-
ture blowouts. Integrity Level (SIL) 2 to SIL 3 with tics themselves — asset management
To take credit for these process di- no added hardware or proof testing. systems and digital communication
agnostics, the user quantifies, in each protocols.
application, the likelihood that the fail- Diagnostics — benefits A centralized asset-management
ure will occur, and the likelihood that The most severe diagnostic condition system (AMS) is useful for several
CHEMICAL ENGINEERING WWW.CHE.COM APRIL 2013 61
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Engineering Practice

reasons. First, it provides early warn-


ing of impending failures in remote
field devices, so maintenance can rem-
edy the problem before it causes fail-
ure. Second, for devices that do fail, a
detailed description of the failure and
context-sensitive remedial action can
speed trouble-shooting. Finally, regu-
lar use of the AMS helps to ensure
consistency, for routine maintenance
and proof tests and the collection of
failure statistics.
It was explained earlier that a key
challenge in safety system design is
obtaining relevant data. The AMS
automatically collects failure statis-
tics for all connected devices, allowing
the user to quantify the probability of FIGURE 5. With a diagnostic that detects line plugging 70% of the time, sensor risk
specific failures under actual operat- falls to 48% of the total PFD, allowing the system to achieve a risk reduction factor of
ing applications and conditions. So 2,077 (SIL-3)
the user can better estimate risks of
specific real-world interface failures, HART is a “hybrid” protocol, com- input cards, racks and power supplies.
including those previously referenced municating diagnostics and other WirelessHART uses a self-organiz-
(line plugging, RTD breakage, an- information in a digital stream su- ing mesh (Figure 6). Each transmitter
tenna coating and so on) This also ap- perimposed at 1,200 Hz on a 4-20-mA contains a smart radio frequency (RF)
plies to time-based conditions — if the analog signal. Newer control systems radio. While RF is a line-of-sight tech-
as-found/as-left audit trail shows that and logic solvers can use both signals nology, it can work through some walls
a device did not require any mainte- at the same time — the analog signal and gratings, and around smaller pipes
nance during the last few proof tests, for control and safety, and the two-way and motors. In a mesh network, some
the user can better justify extending digital HART information for configu- devices can communicate directly with
proof test intervals. ration and diagnostics. An older logic the gateway, and some devices can
solver can also use a HART transmit- only see other devices. A data packet
Digital communications ter, because it simply filters out and will “multi-hop” as necessary until it
A digital communications protocol al- ignores the high frequency HART gets back to the gateway.
lows the user to communicate addi- noise while using the analog signal. Once the system reaches sufficient
tional information from the transmit- To obtain the information in the digi- density, the user can usually assume
ter, including diagnostic information, tal stream, many users have installed that any new device will be able to com-
to the AMS, without additional wiring. “HART multiplexers”, which strip off municate with several other devices,
Users tend to prefer open standards, the HART information and send it to so failure of any one device will not
which ensure access to competitive a parallel AMS. affect network reliability. The network
pricing and best-in-class technology, Not surprisingly, since it leverages is self-organizing, meaning that each
and minimize the risk of obsolescence. existing supplier and user experi- device automatically forms multiple
Although all-digital Fieldbus protocols ence, the dominant protocol for wire- connections to the gateway, which re-
such as Foundation Fieldbus and Profi- less transmitters is WirelessHART, form dynamically as new devices and
bus PA are widely used in basic process also referred to as IEC-62591 [11]. obstacles appear. This ensures high
control, they have not seen adoption Like wired HART, WirelessHART al- reliability with minimal engineering,
in process-industry safety systems be- lows users to add new transmitters and avoids costly site surveys.
yond small demonstrations. for improved process visibility, plus As shown in Figure 7, the wire-
This is probably because the key provide access to complete diagnos- less signals are not used directly by
benefit of the all-digital protocols — tic information from existing or new the safety system. New or existing
multi-drop capability to reduce wiring transmitters, from any supplier, for safety system transmitters connect
cost —is not realized in safety applica- any control system or logic solver. into the logic solver via traditional
tions [9]. Combining process and safety Better, it minimizes cost and physi- HART/4-20-mA wiring. When the leg-
applications, fieldbus transmitters ac- cal space, in both green and crowded acy logic solver does not support HART
count for a growing, but still small mix brownfield installations, by eliminat- input, diagnostic information can be
of new device installations. The vast ing the need for new infrastructure communicated in parallel to the AMS
and growing majority — nearly 75% of — wires, junction boxes, multi-con- using smart antennas. Additional “pro-
new transmitters shipped in 2011 — ductor cables, conduit and wire trays, cess visibility” transmitters needed to
use HART [10]. marshalling cabinets and logic solver improve availability, compliance and
62 CHEMICAL ENGINEERING WWW.CHE.COM APRIL 2013
Modbus/OPC
Native interface
Integration options:
• Modbus serial
• Native interface
• Modbus/OPC

Modbus serial

Hart
data
4-20
Only

FIGURE 6. WirelessHART uses a self-organizing mesh. Data packets will FIGURE 7. Process variables are communicated
take whatever path is necessary to get back to the host, providing reliabil- using traditional 4-20-mA connections to the logic
ity comparable to wired communications solver, while diagnostic information travels via the
WirelessHART to the maintenance terminal

efficiency communicate wirelessly to data. Related is authentication/veri- diagnostics. Diagnostics are available
both the basic process control system fication — only valid devices, and not to detect problems in the device, wir-
and the AMS, and the user can choose hackers, can gain access to the system. ing, process connections and in the
to compare these new wireless trans- Finally, even the most secure design process itself. For maximum benefit,
mitters to the wired safety-system can be defeated by poor password/ information should reach operators
transmitters to improve diagnostic cov- code management — human error. and maintenance personnel in real-
erage. Installation costs are minimized To add a new device to the network, time, with context-sensitive remedial
when the devices are battery powered, the user manually inputs the net- action. Logging all diagnostics and
though the need to install and main- work name and “join key” using the maintenance action from a central
tain devices in hazardous areas limits familiar HART handheld, but only the asset management system will ensure
battery capacity. Although devices can system-generated, encrypted rotating consistency, and simplify collection of
be configured to communicate every key is broadcast over the network. failure statistics. Historically, users
second, with current battery and radio used multiplexers to obtain this di-
technology users are achieving 3- to 10- Wrapping up agnostic information. Open protocols
year battery lives with 4- to 30-second The safety system designer’s first ap- such as WirelessHART now provide
update rates. proach to minimize risk should be to im- the same benefits at a much lower
Security is important because wire- prove strength through best practices. installed cost. ■
less data and devices can be accessed What cannot be eliminated should be Edited by Suzanne Shelley
from outside the plant fence, bypass- avoided via a diverse technology that
ing the usual plant security. All data is resistant to common cause failures. Authors
should be sent with encryption, so What remains should be diagnosed, Stephen Brown is a senior
someone listening in will not be able using a combination of new wired and safety and control systems en-
gineer with E.I. du Pont Nem-
to decode the message and steal the wireless measurements, and device ours & Co. (Phone: 304-863-
4727; Email: stephen.r.brown@
dupont.com). He has 23 years
of experience in control and
safety systems and has been
References involved with the ISA84 Com-
6. Fox, A. and Patterson, D., Self-Repairing mittee. Brown holds a degree
1. Brown, S., Menezes, M., Design Safety Instru- Computers, Sci. Am., June 2003.
mented Systems with Relevant Data,Chem. in electrical engineering from
Eng., pp. 54–58, July 2003. 7. Liptak, B., “Process Measurement and Anal- Carnegie Mellon University.
ysis,” CRC Press, 2003. Mark Menezes manages Em-
2. Brown, S., Menezes, M., Measurement Best erson’s measurement business
Practices for Safety Instrumented Systems, 8. Menezes, M., Improve Plant Safety Through
Advanced Measurement Diagnostics, Chem. in Canada (1421 Samuelson
Chem. Eng., pp. 66–72, Sept 2006. Circle, Mississauga Ont., Can-
Eng., October 2000.
3. Menezes, M., When Your Plus and Minus ada L5N 7Z2; Phone: 416-459-
Doesn’t Add Up, Flow Control, January 9. Welander, P., Safety on Fieldbus, Control 5935; Email: mark.menezes@
2005. Eng., June 2009. Emerson.com.). He holds a
B.S.Ch.E. from the University
4. Pollack, A., Reactor Accident in Japan Imper- 10. “2010 Pressure Transmitter Worldwide Out- of Toronto, and an MBA from
ils Nuclear Program, Feb 24, 1996, New York look Study,”ARC Advisory Group, USA. York-Schulich University in
Times, p. A-1. 11. Boyes, Walt, All Quiet on the Wireless Front, Toronto. Menezes has 22 years
Control, August 2011, p. 30. of experience in industrial
5. Menezes, M., Improve Compressor Safety & automation, specializing in
Efficiency with the Right Pressure Transmit- control systems, loop controllers and flow mea-
ters, Control Solutions, November 2001. surement.

CHEMICAL ENGINEERING WWW.CHE.COM APRIL 2013 63

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