New technologies address process safety

17 August 2012

At the Emerson Global User Conference, held in Dusseldorf in May, three new technologies were announced to help reduce the complexity of process manufacturing safety, in line with the company’s continuing efforts to enhance end-user’s safety performance, including a total-loop approach to safety instrumented systems (SIS).

CHARM I/O technology is now available on DeltaV SIS logic solvers.
CHARM I/O technology is now available on DeltaV SIS logic solvers.

Jim Nyquist, president process systems and solutions business at Emerson, explained the business case for safety: “The project environment today is a challenging one. Projects are getting larger and more complex. Schedules are also compressing and time to market has become a more critical factor, with the additional issues of budgets being compressed. However, safety is still critical and there can be no shortcuts. As history has shown the real cost of safety failures only becomes apparent after an incident and these can have a host of wide-ranging and long-term effects.

“Emerson has spent a great deal of time designing predictive intelligence into its products to help predict failures before they happen alerting operators to take action before a situation develops. We introduced the first digital integrated SIS with Delta V SIS a few years ago. This did not just look at the condition of the process, but also at the health of all equipment within the safety loop.”

DeltaV SIS logic solver with TÜV-approved CHARM I/O technology
The DeltaV SIS logic solver incorporates the technologies of the DeltaV SIS Logic Solver and the DeltaV system CHARM I/O. The resulting enhanced SIS design simplifies project execution and adds schedule flexibility by reducing design and engineering requirements.
Based on Human Centered Design (HCD) principles, the new Logic Solver architecture uses electronic marshalling and CHARM I/Os to eliminate the need for conventional marshalling, simplifying installation and commissioning.

The system can be implemented as a standalone SIS solution, natively integrated as part of a DeltaV installation, or connected to any DCS, with the CHARM technology reducing the number of steps needed to design, install and operate these solutions.

The approach seems to have independent approval. Barry Young, principal analyst at the ARC Advisory Group, said: “We have closely monitored the development of both the DeltaV SIS product and Emerson’s CHARM technology since their inception, and we think that the use of CHARM technology in the DeltaV SIS system is an approach that could provide significant value for the company’s end users.”

The CHARM Smart Logic Solver (CSLS) provides the same functionality as the existing SLS 1508 logic solver, but extends the previous 16 I/O limit per logic solver to 96 I/O CHARM capacity. In inputs are software-assignable to any of the logic solvers on local safety network, increasing flexibility of configuration and wiring possibilities.

TÜV-certified SIS digital valve positioner
The latest evolution of the FIELDVUE platform, the DVC6200 SIS valve positioner, extends Emerson’s Fisher DVC digital valve controller technology into safety-loop operation too. The explosion-proof module is TÜV certified for use in safety applications and is equipped with on-board diagnostics that detect a high percentage of potential valve failures while the valve remains in operation. By performing a partial valve stroke test, the valve positioner can determine if the valve is stuck open, has inadequate torque, is too slow, exhibits high friction, or has a broken shaft. Determining the health of the device on a periodic basis can enable maintenance of the final safety element to take place in a prioritised and planned fashion. It also the added capabilities of HART 7 communication and linkage-less, non-contacting travel feedback technology.

TÜV-certified digital overspeed protection system
Bjorn Salomon, general manager of Emerson’s Machinery Health management business, describes the TÜV-certified digital overspeed protection system product as offering ‘a last line of defence. He said: “Turbo machinery is a very costly and critical asset in an operation and runs at very high speeds. When running at a steady state there is rarely a problem, with controllers in place to ensure the machinery is running properly. The machines are generally held in a steady state of operation for 90% of the time. However, 50% of safety incidents happen in the remaining 10% of the time, during transient operations such as start-up, coast downs, or load changes.”

The CSI 6300 SIS is certified for Safety Integrity Level (SIL) 3 applications, where it protects rotating equipment from improper start-up or overspeed conditions. It detects the rotational speed of the rotating equipment and acts to shut it down if the speed reaches the safe operating limit. This prevents equipment damage or hazardous operation due to surging that can be caused by unplanned load swings. It can also detect when a rotating device moves in the wrong direction, a condition that can occur particularly during start-up.

Salomon concludes: “With CSI 6300 SIS users are assured that their overspeed protection system complies with today’s safety standards, without the complexity of having to demonstrate that existing equipment meets the latest requirements.” The system complies with DIN EN 61508:2010 aas the European Machine Directive 2006/42/EG and API 670.

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