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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
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
Exida
Engineering Practice
Engineering Practice
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.