Welcome to Heartbeat Technology!

Transcription

1 Products Solutions Services Welcome to Heartbeat Technology! Directive 17 Compliant, TUV Certified! Technology Day Calgary May 2015 Heartbeat Technology Slide 1

2 Addressing Your Metering Challenges Measurement & Compliance Manager: How do I ensure our AER D17 requirements are met? Quality/Compliance Maintenance Manager: Is my meter working properly? Availability Process Engineer: Is my process running as designed? Safety Slide 2

3 Why Check Flow Meters? Slide 3

4 Traditional Meters May Lose Accuracy Turbine meters: Over spinning damage Worn or broken blades PD Meters: Debris in line Entrained gases Slippage due to viscosity Differential Pressure: Worn edges of element Element deformed from excess pressure Slide 4

5 Intelligent Field Devices Today! Why keep sending the meter back for re-calibration? - Most meters returned for re-calibration do not require adjustment In fact only Endress+Hauser Vortex meters have a lifetime Calibration! Coriolis Vortex Magmeter Ultrasonic Slide 5

6 Heartbeat Technology The Universal Solution For all Endress+Hauser flow measurement technologies Heartbeat Technology is at the heart of the new Proline flowmeter platform, ensuring reliable measurement operation whatever the flow measurement technology Coriolis Vortex Magmeter Ultrasonic Slide 6

7 Heartbeat Technology - The Elements Heartbeat Technology Heartbeat Monitoring Heartbeat Verification Pass / Fail Heartbeat Diagnostics Slide 7

8 At a glance: What Heartbeat Technology can achieve Diagnostics Verification Monitoring Reliable self-monitoring Continuous, built-in diagnostic functionality Broadest test coverage Quick, concise guidance in case of errors (NE 107) Compliant testing On-demand, effortless procedure Easy handling, no process interruption Electronic quality reporting Condition-based maintenance Permanent reading of process-related variables Impact assessment External trend analysis Slide 8

9 Heartbeat Diagnostics - Standard with Proline Heartbeat Diagnostics Flowmeter health information supports OK Failure Check Process safety Product quality Operation & Maintenance Slide 9

10 Heartbeat Diagnostics FieldCare DTM Conforms to Namur NE 107 Slide 10

11 Why do YOU get YOUR Gas meters verified? D-17 Gas Meters Exception #9 Internal metering diagnostics may be used to determine if the structural integrity of the primary measurement element is within acceptable operating parameters and checked at the same required intervals as an internal inspection. Then internal inspection is not required until an alarm or error is generated by the device or as recommended by the manufacturer. The operator must maintain documentation on the diagnostic capability of the measurement system and make it available to the ERCB on request. An initial baseline diagnostic profile must be performed and documented during the commissioning process. Slide 11

12 Why do YOU get YOUR Liquid meters verified? D-17 Liquid Meters Exceptions 1) If a meter used to measure fluids at flow-line conditions is a type that uses no internal moving parts (e.g., orifice meter, vortex meter, cone meter, Coriolis meter, ultrasonic meter), it does not require proving, provided that all the following conditions are met: The flow through the meter must be continuous (not intermittent) or the meter must qualify for bench proving or be a Coriolis-type meter with sufficient structural integrity internal diagnostics (see below) and maintained within the rates specified by the meter manufacturer as providing accurate measurement. Slide 12

13 Why do YOU get YOUR MARP Meters verified? Heavy Thermal Oil All steam measurement devices must be calibrated/proved/verified on an annual basis or as otherwise stated in Section 2.5 or above All water measurement devices must be calibrated/proved/verified on an annual basis or as otherwise stated in Sections 2.6 and All solvent injection measurement devices must be calibrated/proved/verified on an annual basis in accordance with Section 2. Slide 13

14 Now really why do YOU get YOUR meters verified? These meters are how royalties are calculated and resources are conserved or consumed. If you re over reporting this is a financial loss! If you re under reporting you might have to go back one day and make adjustments which could become a financial loss! Slide 14

15 Terminology: Accredited, Calibration, Proving, Verification Accreditation demonstrates technical competence for a defined scope and operation of a laboratory quality management system through 3 rd party audit compliance and traceable calibration. Result: Quality Calibration Calibration is a performance comparison of a meter under test and a standard under laboratory conditions. Result: Calibration Factor Proving is a performance comparison of a meter under test and a standard under actual process conditions to account for installation and actual process fluid effects. Result: Meter Factor Verification is a functional test comparing a meter under test to a known standard to determine quality of measurement which may be traceable to laboratory calibration. Used to extend Calibration intervals. Result: Pass / Fail indicating that the Calibration is still valid. Slide 15

16 Endress+Hauser Portfolio of testing methods Verification On-site On-site Calibration In Laboratory Heartbeat Verification Fieldcheck (not for new Proline) Mobile Bench Prover Fixed Bench Prover (Edmonton 2015/2016) Flow-meter functional assessment (comparison still vs. traceable references) Internal parameters Operating conditions Metrological performance assessment (adjustment via calibration factor, certificate) Primary measurand ( ) Reference conditions (fluid, p, T) Slide 16

17 Flowjack: First signal simulator for entire flow portfolio Uncontested benefits: Quick and reliable testing Flowmeter remains in place Flowmeter calibration data manually inputted Traceability of all components Good proof-test coverage Flowjack Improvement areas: Cumbersome equipment Manual reports Mandatory trip to the field Disconnected output, interruption of measurement Potential handling errors Slide 17

18 Fieldcheck: Recognized method (signal simulation) Uncontested benefits: Quick and reliable testing Flowmeter remains in place Flowmeter calibration data automatically downloaded Automated report Traceability of all components Excellent proof-test coverage Fieldcheck TM Improvement areas: Cumbersome equipment Mandatory trip to the field Disconnected output, interruption of measurement Potential handling errors Slide 18

19 Products Solutions Services Lets Perform a Heartbeat Verification Now! Slide 19

20 Heartbeat Verification to succeed Fieldcheck Similar functionality, now embedded in the device electronics Permanently available, no mandatory accessories Accessible via all available interfaces Testing of the entire signal chain without service interrupt Simplistic handling, clear / automated procedure Verification results stored in the device (8 most recent datasets) FieldCare PC can be connected, so the verification DTM can upload results, generate a report, and manage the entire verification history Heartbeat Technology Slide 20

21 Heartbeat Verification vs. Fieldcheck Fieldcheck External Simulation and sensor checking 30 to 60 minutes Proof-test coverage 90% or better Heartbeat Verification Built-in, with remote options Embedded test functionality App. 10 minutes Total test coverage* TTC > 95% acc. to IEC *Cumulative rating of safe failure across entire device electronics Slide 21

22 Heartbeat Verification - Independently Certified by TUV Detection by Heartbeat Verification Verification Proof-Test λdu -Dangerous Undetected Failure λdd -Dangerous Detected Failure λsd -Safe Detected Failure λsu -Safe Undetected Failure SFF Safe Failure Fraction including Verification is upto 98%. Continuously covered by Heartbeat Diagnostics Slide 22

23 Heartbeat Verification - TUV Certified, Directive 17 Compliant! Due to our Safety-by-Design philosophy Endress + Hauser flow meters that have Heartbeat Technology are independently certified by TUV and comply with the requirements of AER Directive 17. Slide 23

24 Safety in perfection developed according to IEC Safety in hazardous environments Minimized risk of random failures Simple and seamless integration into existing plant infrastructure 4 to 20 ma Remote monitoring, verification PLC, DSC, Remote I/O Control system Zone 1 Cl.I Div1 Zone 2 Cl.I Div2 Transmitter supply units Asset management tool, e.g. FieldCare Slide 24

25 Heartbeat addresses your most serious challenges Safety Quality Availability Slide 25

26 Challenges in the Process Industry? Maintenance Costs: High costs and constraints for preventive maintenance D17 Compliance: Keep up trust in the integrity of measurements Erosion inside the measuring tube of a Coriolis flowmeter Slide 26

27 What Heartbeat Technology can do PDF Heartbeat Diagnostics: Greatly reduced risk of failure Heartbeat Verification: Clarity and evidence without process interruption Heartbeat Monitoring of process-related parameters Slide 27

28 What s in it for you Full flexibility to schedule proof-tests, enables cost savings Proof of functional reliability, no discussion about the verification process Informed decisions about flowmeter maintenance Slide 28

29 Heartbeat Technology what makes it unique Reliability Seamless integration Uniform handling Audited and attested: Traceable, redundant references inside the device Large variety of seamless integration options For all new Proline flowmeters Slide 29

30 Heartbeat Technology reliable self-monitoring IEC audits completed ISO 9001 conformity certification, audits completed on Proline 200 Long-term stability Redundant internal references Traceable factory calibration according to ISO on accredited facilities Measuring electronics Test electronics Dual frequency generators (Promass, Prowirl) Multiple voltage references (Promag) Flow measurement (, ) Electronic modules Ex-factory status is stored invariably in the device Each single test is passed only if the current parameter value remains within tight, unchangeable tolerances supporting the device specification Slide 30

31 Heartbeat Verification onsite access SIL loop integrated via 4..20mA HART Asset management tool, e.g. FieldCare Communication interface FXA 291 Control cabinet Slide 31

32 Heartbeat Verification access via HART modem SIL loop integrated via 4..20mA HART HART Modem Asset management tool, e.g. FieldCare Control cabinet Slide 32

33 Heartbeat Verification access via Foundation Fieldbus Honeywell DCS environment FF function block MDO Start Verification FF function block DI PASS: Value 1 FAIL: Value 0 Slide 33

34 Heartbeat Verification access via Foundation Fieldbus Honeywell DCS environment Asset management tool Field Device Manager FieldCare Slide 34

35 Heartbeat Technology fundamentals Long-term stability Redundant internal references Traceable factory calibration Electronic modules Designed to minimize risk of failure 100% testing against traceable references Completed device Accredited calibration Primary measurand (, ) Slide 35

36 Total Test Coverage from sensor to outputs Flowmeter development according to IEC Continuous self-monitoring based on NE 107 Example: Proline Promass F 200 ISEM, CPU Temperaturesensors I/O Modul Exciter coil Power Supply Pick-up coil Diagnostic messages securely stored in the event logbook Slide 36

37 Proline Promass: Overview of test groups System (AMS. PLC) Continuous On demand I/O module 4 20 ma output loop-back test Sensor electronic module Zero-point tracking Reference clock Reference temperature Sensor Inlet / Outlet pick-up coil Measuring / Carrier tube temperatures Pick-up coil symmetry Frequency lateral / torsion mode Sensor Integrity (HBSI) Electromechanical integrity of Promass Proline Promass 100 / 300 / 500 Slide 37

38 Traceable internal references for measurement + testing High-precision frequency generators Continuous synchronous-run test in the device reliably detects ambient and process influences potentially causing drift in the electronics Traceable test of each module against accredited reference standard prior to traceable factory calibration of the entire device ISEM Impulse count in given time window <0.01% 20 MHz Quartz 20 MHz Quartz Slide 38

39 Current output loop-back test Drift and aging of electronics Internal connectivity problems External influences (load resistance) CPU I/O module ma 1% + 100μA Proline Promass 100 example Slide 39

40 Heartbeat Verification electronic Pass / Fail report Promass F 200 Slide 40

41 Verification DTM for FieldCare asset management tool Slide 41

42 Products Solutions Services Lets look at our Heartbeat Verification Report! Slide 42

43 Proline Prowirl 200: Summary of test groups On demand Main Electronic Module Supply Voltage I/O module 4 20 ma output loop-back test Sensor electronic module Reference frequency drift DSC sensor reference Temperature measuring path DSC sensor measuring path Sensor DSC Sensor Temperature Sensor Only Prowirl C (Canada) has inspection ports for shedder bar inspection Proline Prowirl 200 Slide 43

44 DSC sensor: Gap capacity difference test Capacitive sensor to count the vortex frequency Warning level yields a Fail in the test, but still allows to measure Small impact on measurement accuracy, strong indicator for device functionality C 1 C 2 dc = C 2 C 1 Level dc in pf Normal 0 to < 4.6 Warning 4.6 to 6.8 Failure > 6.8 Slide 44

45 Proline Promag: Summary of test groups Main Electronic Module Supply Voltage On demand I/O module 4 20 ma output loop-back test Sensor electronic module Reference voltage Linearity of electrode measuring circuit Offset of electrode measuring circuit Sensor Coil current shot time Coil hold voltage Coil current Proline Promag 100/200/400 Slide 45

46 Proline Promass condition monitoring applications Types of process impact Relevant parameters Entrained gas, cavitation, as well as empty tube Coating build-up, corrosion, erosion Tube damping Damping fluctuation Frequency fluctuation Tube damping Signal asymmetry Resonance frequency Interpretation requires sound understanding of the measuring point and the process influence on the oscillation system of the specific Coriolis device type Slide 46

47 Heartbeat Monitoring for entrained gas Entrained gas is a challenge in Coriolis measurement in general. In can therefore be useful to monitor its impact below the limit values of Heartbeat Diagnostics Diagnostic threshold Tube damping = Exciter current Amplitude Critical peaks: factor 100 to 1000 Base value Tolerated e.g. up to factor 30 Tube damping is also a parameter of continuous diagnostics, and leads to a warning above a threshold of 200,000 A/m. Damping fluctuation and frequency fluctuation are powerful indicators of cavitation and entrained gas as well. Slide 47

48 Heartbeat Monitoring: Coating build-up in the tube If the fluid s density and viscosity are stable, coating build-up can be detected by decreasing frequency, and concurrent increase in tube damping or signal asymmetry. Tube damping e.g. +10% Signal asymmetry Resonance frequency Base value e.g. +10% e.g. - 1% The density measurement can be tracked in addition, if the fluid is unchanged. Slide 48

49 Heartbeat Monitoring: Corrosion Corrosion may occur in manifold forms, so condition monitoring requires a variety of parameters, particularly here. Tube damping Signal asymmetry Gradual, steady drift Resonance frequency Base values The density measurement can be tracked in addition, if the fluid is unchanged. Slide 49

50 Heartbeat Monitoring: Abrasion Abrasion particularly impacts the curved sections inside the tube. Promass 100 offers the HBSI test, Promass 200 does not! Promass I 100 Straight / Titanium mono-tube, suitable in abrasion use cases Only Promass I offers HBSI as a continuous monitoring parameter! Signal asymmetry (Inlet / outlet amplitude ratio) HBSI: Heartbeat Sensor Integrity Tolerance 25% Base values Tolerance 2% / 4% HBSI: Warning at 2%, failure at 4% Slide 50

51 Heartbeat Technology Technology beating reliably! Safety Quality Availability Slide 51

52 Products Solutions Services Questions? We have included some of your questions and answers in the next slides Slide 52

53 Questions & Answers #1 Question On slide 21 the Presenter mentions that the Test Coverage is across the entire device electronics, does that mean only the electronics are tested by Heartbeat Verification. Answer TUV certifies the device s ability to identify a fault and all the software and tests are carried out in the electronics. This means while we are testing the sensor integrity it is the electronics that tests and verifies the sensor and ultimately generates a fault. TUV is interested in the ability for the device to identify and annunciate a fault safely meaning the fault does not go undetected. Slide 53

54 Questions & Answers #2 Question On slide 8 the Presenter mentioned that the only 4 wire devices would have Heartbeat Monitoring. Answer All Proline 3 devices (2 & 4 wire) come with Heartbeat Diagnostics which is a nearly full test coverage of the complete device! Optionally Heartbeat Verification is an ondemand test that takes the test coverage up to 98%. While Heartbeat Monitoring allows you to monitor in to your DCS, continuously in real-time device parameters that normally would only be tested on-demand (ie. Heartbeat Verification ) and this can only be done with the 4 wire devices. This is just a matter of power consumption or availability. Slide 54

55 Questions & Answers #3 Question Why do you call the presentation TUV Certified, Directive 17 Compliant! Answer Heartbeat Verification is an integral part of the overall proof test for these Endress+Hauser SIL rated devices. TUV is an independent 3 rd party that has tested and certified these devices to have a high availability and safe failure meaning if a fault was to occur the device identifies it before a dangerous situation occurs. The SIL device and non SIL device uses all the same components. These devices are Directive 17 compliant even though AER doesn t endorse, register or certify devices so you have Certification and Compliance with Endress+Hauser! Slide 55

56 Products Solutions Services Thank you very much for your attention Slide 56