Wireless Technology
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The document discusses using wireless technology to monitor process safety key performance indicators (KPIs). It notes that wireless monitoring can provide real-time visibility into critical areas like steam traps and safety showers to improve safety compliance and efficiency. Monitoring technologies like acoustic transmitters and discrete I/O transmitters integrate with existing wireless networks to gain insights into hazards and inefficiencies.
Wireless Technology
- 1. WirelessWireless TechnologyTechnology meetingmeetingTechnology,Technology, meetingmeeting your challenges toyour challenges to monitor Processmonitor Processmonitor Processmonitor Process Safety KPIsSafety KPIs ISA Saudi Section - ISA Dinner Meeting 25th March 201325 March 2013 Mohamed Salman CFSE, TUV FSE T h i l S l C lTechnical Sales Consultant Emerson Middle East & Africa N d MNadeem Menon Wireless Marketing Manager Emerson Middle East & Africa
- 2. Not safeNot safe ☺☺ You cannot use wireless in aYou cannot use wireless in a Safety Instrumented SystemSafety Instrumented System Emerson Confidential Safety Instrumented SystemSafety Instrumented System
- 4. How your Process Safety is doing?How your Process Safety is doing?How your Process Safety is doing?How your Process Safety is doing? Personal Accidents Major Hazard RisksMajor Hazard Risks Emerson Confidential
- 5. Personal Safety / Process SafetyPersonal Safety / Process SafetyPersonal Safety / Process SafetyPersonal Safety / Process Safety “A number of past CSB investigations have found companies focusing on personal injury rates while virtually overlookingg j y y g looming process safety issues – like the effectiveness of barriers against hazardous releases, automatic shutoff system failures, activation of pressure relief devices, and loss of containment of Emerson Confidential liquids and gases,” CSB Chairperson Dr. Rafael Moure-Eraso.
- 6. How your Process Safety is doing?How your Process Safety is doing?How your Process Safety is doing?How your Process Safety is doing? P S f tProcess SafetyPersonal Safety Focusing routine personal injury Focusing on managing theg p j y and fatality data such: •Dropped objects •Trips and fallen potential for catastrophic accidents. Emerson Confidential
- 7. Managing (catastrophic) hazardous eventsManaging (catastrophic) hazardous events –– through independent protection layersthrough independent protection layers Managing (catastrophic) hazardous eventsManaging (catastrophic) hazardous events –– through independent protection layersthrough independent protection layers P i t ti Emergency response x x Mitigate Active protection (example: Relief valve Passive protection (example: bund) SIS (SIF ) (example: Relief valve, rupture disk)Incident Prevent BPCS (HMI & Alarm Handling) operator intervention l (SIFs) Trip level alarm BPCS (Process Control) Process Value normal behaviour (HMI & Alarm Handling)process alarm Emerson Confidential (Process Control)a ue
- 8. Why it is important to look at the ProcessWhy it is important to look at the Process Safety KPIs?Safety KPIs? Why it is important to look at the ProcessWhy it is important to look at the Process Safety KPIs?Safety KPIs? International Association of Oil and GasInternational Association of Oil and Gas Producers (OGP) Report No. 456 November 2011 Emerson Confidential November 2011
- 9. Process Safety Indicator Pyramid (FromProcess Safety Indicator Pyramid (From API RPAPI RP 754754)) Process Safety Indicator Pyramid (FromProcess Safety Indicator Pyramid (From API RPAPI RP 754754)) Select Tier 3 & Tier 4 KPIS to Tier 1 LOPC event of greater consequence Monitor critical barriers at facilities q Tier 2 LOPC events of lesser Consequence Tier 3 Challenges to Safety systems Tier 4 Operating discipline & management system performance indicators Emerson Confidential Note: OGP outlined six recommended step approach for selection and review of KPIs (based on UK HSE)
- 10. What’s Needed:What’s Needed: An Integrated Safety CultureAn Integrated Safety Culture What’s Needed:What’s Needed: An Integrated Safety CultureAn Integrated Safety Cultureg yg yg yg y People & Process System Technology y Design Technology Emerson Confidential
- 11. Process Safety MonitoringProcess Safety Monitoring -- ApplicationsApplicationsProcess Safety MonitoringProcess Safety Monitoring -- ApplicationsApplications Steam Trap monitoring – Effects of Failed Steam Traps– Effects of Failed Steam Traps – Prevent Water Hammer in Steam lines. – Pressure Relief Valve monitoringg Solution - Rosemount 708 Acoustic transmitter – Steam Logic softwareSteam Logic software Safety Shower monitoring and Eye Wash Station H d b L k d t ti it iHydrocarbon Leak detection monitoring Unlock the power of HART diagnostics Emerson Confidential
- 12. Why monitor Steam TrapsWhy monitor Steam TrapsWhy monitor Steam TrapsWhy monitor Steam Traps As steam travels through piping heat is lost to ambientsteam pipe heat is lost to ambient Some of the steam condenses and collects in the low points This leads to: – Inefficient heat transfer – Safety concerns from steam water/steam hammer Steam traps remove this condensate while minimizingcondensate g steam loss steam trap line Steam Trap condensate Emerson Confidential
- 13. Steam Trap FailureSteam Trap FailureSteam Trap FailureSteam Trap Failure Safety Cold) – Water in piping can result in water (steam)hammer, pressure transients, and erosion corrosion of piping Plant personnel and equipment are placed at risk Shut(C – Plant personnel and equipment are placed at risk Reduced Thermodynamic Efficiency W t h t t f f lt i d d FailedS – Water on heat transfer surfaces results in decreased thermal performance, product throughput and quality Energy / Steam Loss n Energy / Steam Loss – Failed high value steam traps can cost $10k - $25k/yr in lost steam edOpen Blow rough) in lost steam Faile (B Thr Emerson Confidential
- 14. Failed Cold Traps Pose a Risk toFailed Cold Traps Pose a Risk to Personnel and EquipmentPersonnel and Equipment Failed Cold Traps Pose a Risk toFailed Cold Traps Pose a Risk to Personnel and EquipmentPersonnel and Equipment Stream traps remove condensate from piping preventing: Steam Blast Jolts Midtown, Killing Onefrom piping preventing: – Erosion and corrosion of piping reducing the lifespan of plant equipmentq p – Inefficient heat transfer across heat exchangers, distillers, reactors and crackers If this steam is not removed not only is there inefficient heat transfer, but: “State investigators have focused on a steam trap about 10 feet from the blast site, which should have – Safety hazard: Water in steam causing erosion/corrosion of plant equipment , removed cooled water droplets from the pipe.” New York Post The mayor said the explosion appeared to have been caused by cold water that reached the pipe. “Cold – Safety hazard: Water flashing to steam and causing pressure surges y p p water apparently causes these to explode,” he said. The New York Times Click to read more: New York Post The New York TimesTo read more: Emerson Confidential The New York TimesTo read more: http://www.nypost.com/p/news/regional/item_QUb1 OKwqiipzJP2YaP8BfM
- 15. Failed Cold Traps Pose a Risk toFailed Cold Traps Pose a Risk to Personnel and EquipmentPersonnel and Equipment Failed Cold Traps Pose a Risk toFailed Cold Traps Pose a Risk to Personnel and EquipmentPersonnel and Equipment Stream traps remove condensate from piping preventing: E i d i f i i Water Hammer – Erosion and corrosion of piping reducing the lifespan of plant equipment I ffi i t h t t f– Inefficient heat transfer across heat exchangers, distillers, reactors and crackers If this steam is not remo ed not onlIf this steam is not removed not only is there inefficient heat transfer, but: Safety hazard: Water hammer Water Impingement Steam Line Rupture – Safety hazard: Water hammer pressure surges put plant personnel and equipment at risk – Safety hazard: Water in steam causing erosion/corrosion of plant equipment Emerson Confidential p q p
- 16. Improve Safety and Reduce the Impact ofImprove Safety and Reduce the Impact of Releases with PRV MonitoringReleases with PRV Monitoring Improve Safety and Reduce the Impact ofImprove Safety and Reduce the Impact of Releases with PRV MonitoringReleases with PRV Monitoring Keep your operation running safely and efficiently, and reduce your environmental impact by havingenvironmental impact by having constant visibility to all your critical PRVs Emerson Confidential
- 17. Enhance Safety, Improve EnergyEnhance Safety, Improve Energy efficiency and Protect Key Assetsefficiency and Protect Key Assets Enhance Safety, Improve EnergyEnhance Safety, Improve Energy efficiency and Protect Key Assetsefficiency and Protect Key Assets The Rosemount 708 Wireless Acoustic Transmitter Gives you real-time visibility to all your critical steam trapsGives you real time visibility to all your critical steam traps Provides information that enables you to make good decisions Is fast and easy to install and maintain Is proven technology that’s easy to use Emerson Confidential
- 18. Wireless Discrete I/O Transmitter with EnhancedWireless Discrete I/O Transmitter with Enhanced CapabilitiesCapabilities Wireless Discrete I/O Transmitter with EnhancedWireless Discrete I/O Transmitter with Enhanced CapabilitiesCapabilitiespppp Momentary Input Plunger Lift Controlg Mechanism monitoring Discrete Output Switch Technologies Proximity Switches Discrete Output Valve Control Motor Control Proximity Switches GO Switches Float Switches Pump Control Lights Float Switches Pressure Switches Flow Switches Hydrocarbon Leak Detection Alarms Hydrocarbon Leak Detection Tyco TraceTeK Cable Tyco Fast Fuel Sensor – Tank monitoring – Valve monitoring – Pipeline monitoring
- 19. 702702 Wireless DiscreteWireless Discrete InputInput702702 Wireless DiscreteWireless Discrete InputInput CLOSEDOPEN CLOSED Switch 702 Gateway Control System y System
- 20. 702702 Wireless DiscreteWireless Discrete OutputOutput702702 Wireless DiscreteWireless Discrete OutputOutput OFFON ON OFFON Output 702 Gateway Control System p y System
- 21. Safety Shower + Eye wash Station MonitoringSafety Shower + Eye wash Station MonitoringSafety Shower + Eye wash Station MonitoringSafety Shower + Eye wash Station Monitoringy y gy y gy y gy y g Rosemount 702 Transmitter + TopWorx GO Switch = Wireless monitoring Both Safety Shower and Eye Wash can be monitored with one 702monitored with one 702 transmitter Emerson Confidential
- 22. Regulations:Regulations:Regulations:Regulations: ANSI Z358.1.2009 - Weekly inspections and annual functional tests OSHA 1910.151B - Response within 4 minutes or less EN 15154 (E ) W kl i ti d l f ti l t tEN 15154 (Europe) - Weekly inspections and annual functional tests Emergency response in 4 minutes or less Regulations drive the need for:Regulations drive the need for:Regulations drive the need for:Regulations drive the need for: Emergency response in 4 minutes or less Recommended Weekly inspections Annual functional tests Emerson Confidential
- 23. Wireless Monitoring SolutionWireless Monitoring Solution for Eye Wash and Safety Showerfor Eye Wash and Safety Shower Wireless Monitoring SolutionWireless Monitoring Solution for Eye Wash and Safety Showerfor Eye Wash and Safety Showerfor Eye Wash and Safety Showerfor Eye Wash and Safety Showerfor Eye Wash and Safety Showerfor Eye Wash and Safety Shower Eye wash and safety showers are commonly installed in chemical plants, refineries, factories,p , , , and any work areas where there is any risk or eye and/or face damages due to the presence of corrosive or irritating materialsg Customer’s Issues Unable to monitor any activation of these devices Manual recording of periodic checks and maintenance BenefitsBenefits Safety: Improve safety team response to a person in trouble Regulatory Compliance: Provide timestamp data on shower use for incident reporting and safety compliance audits Emerson Confidential
- 24. Hydrocarbon Leak DetectionHydrocarbon Leak DetectionHydrocarbon Leak DetectionHydrocarbon Leak Detection 702 Wireless Liquid Hydrocarbon L k D t tiLeak Detection – Rosemount’s 702 Transmitter integrated with: Fast Fuel Sensor integrated with: – Tyco® TraceTek® Fast Fuel Sensor1 Sensor – Tyco® TraceTek® Sensor Cable Emerson’s Smart WirelessEmerson s Smart Wireless and Tyco’s TraceTek technologies combine to TraceTek Sensor Cable g provide leak detection. Emerson Confidential TraceTek Sensor Cable
- 25. Leak Detection – Meeting RegulationsLeak Detection – Meeting Regulations Increasing Regulations for storage tanks Alaska CaliforniaAlaska California Florida & others Other Countries Globally Emerson Confidential
- 26. ApplicationsApplications Leak Detection Applications – Tank spill applications– Tank spill applications • sump installations • Around tank Floating roof / leak seal detection– Floating roof / leaky seal detection – Pipeline leaks in risk areas – Overfill notification F l l k– Fuel leaks • For example around backup generators Pressure in Fire water linePressure in Fire water line NitrogenNitrogen blanket pressure monitorblanket pressure monitor for remote tanksfor remote tanks Pressure in Fire water linePressure in Fire water line NitrogenNitrogen blanket pressure monitorblanket pressure monitor for remote tanksfor remote tanks Emerson Confidential
- 27. Gain Access to Advanced DiagnosticsGain Access to Advanced Diagnostics Plugged LinePlugged Line DetectionEnhanced Valve Capabilities Online Configuration & Diagnostics pH Probe Monitoring In-situ Meter Verification Emerson Confidential g
- 28. PersonnelPersonnel –– Safety mustering and MobileSafety mustering and Mobile WorkerWorker -- VoiceVoice & Video& Video PersonnelPersonnel –– Safety mustering and MobileSafety mustering and Mobile WorkerWorker -- VoiceVoice & Video& Video Stn 1 f fThe world’s first hands-free wireless and wearable audio- data & video communication Stn 2 Stn 3 Emerson Confidential data & video communication system.
- 29. RealReal--time Visibility to Critical Steam Trapstime Visibility to Critical Steam TrapsRealReal--time Visibility to Critical Steam Trapstime Visibility to Critical Steam Traps Smart Wireless system Monitor traps throughout your plant, even in remote and hard-to-reach locations 99% data reliability Works with existing WirelessHART® network Emerson Confidential
- 30. Emerson’s Smart Wireless ProvenEmerson’s Smart Wireless Proven TechnologyTechnology Emerson’s Smart Wireless ProvenEmerson’s Smart Wireless Proven TechnologyTechnologyTechnologyTechnologyTechnologyTechnology 11..44+ Billion+ Billion hourshours operating experienceoperating experience Hundreds of Thousands ofHundreds of Thousands ofHundreds of Thousands ofHundreds of Thousands of SmartSmart WirelessWireless field devicesfield devices Tens of Tho sands of WirelessTens of Tho sands of WirelessTens of Thousands of WirelessTens of Thousands of Wireless Field NetworksField Networks http://www2.emersonprocess.com/en-US/plantweb/wireless/Pages/WirelessHomePage-Flash.aspx Emerson Confidential