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Pepperl fuchs 2011 Emerson Global Users Exchange  Intrinsically Safe CHARMS Session 8-2387
 

Pepperl fuchs 2011 Emerson Global Users Exchange Intrinsically Safe CHARMS Session 8-2387

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Check out the Intrinsically Safe CHARMS joint presentation between Pepperl+Fuchs and Emerson from the 2011 Emerson Global Users Exchange

Check out the Intrinsically Safe CHARMS joint presentation between Pepperl+Fuchs and Emerson from the 2011 Emerson Global Users Exchange

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  • An intrinsically safe apparatus never stands alone. Generally, it is part of a system in which the certified components must be used in a way to guarantee the safety of the system for the specific application. A simplified schematic of an intrinsically safe system is shown here. As can be seen there are three components to an intrinsically safe circuit: - The field device- Intrinsically safe equipment located in the HAZARDOUS LOCATION - Intrinsically safe barrier-or associated apparatus located in NON-HAZARDOUS LOCATION - Interconnecting wire between the two apparatus The example here is simple because the fault combinations are few and the knowledge of the apparatus safety parameters and cable characteristics are sufficient to verify the safety of the system. A more complex system (combinations of barriers or use of multiple cables) requires a more detailed analysis because the fault combinations to be verified are many and not always evident.
  • An intrinsically safe circuit will always operate below the minimum ignition point during normal and abnormal operation with a 50% safety factor. The following standards contain ignition curves and design requirements for intrinsically safe equipment: UL913 FM3610 CSA C22.2 No. 157 ISA 12.2.01 IEC 60079-11
  • The Zener diode defines the Voc/Uo. There are up to 3 of them in one Barrier. Ex ia requires to be safe even in the event of 2 independent failures. Therefore Ex ia barriers are equipped with 3 parallel connected Zener diodes. Ex ib requires to be safe even in the event of one failure so minimum requriement is 2 Zener diodes and Zone 2 requires to be safe under normal operation condition only (no failure conditions are observed)  1 Zener diode would be enough. The short circuit current Isc/Io is defined by the break threw voltage of the Zener diode(s) divided by the Resistor value. So if you provide a too high voltage to the barrier (in this drawing) the fuse will blow and avoid that a too high voltage will be provided to the field. Even this drawing is SIMPLIFIED!
  • 21 22 21
  • I have added “ Less maintenance and inspection requirements” (to be 100% correct I have to say: according to IEC requirements).

Pepperl fuchs 2011 Emerson Global Users Exchange  Intrinsically Safe CHARMS Session 8-2387 Pepperl fuchs 2011 Emerson Global Users Exchange Intrinsically Safe CHARMS Session 8-2387 Presentation Transcript

  • Application of the Intrinsically Safe CHARMS Modules for Project Savings Session ID: 8-2387
  • Presenters
    • Not pictured : Klaus Erni
  • Introduction
    • Application of the Intrinsically Safe CHARMS Modules
    • Intrinsic Safety Basics
    • IS CHARMS
    • Application of IS for DeltaV Systems
    • Application of IS CHARMS
  • You Are All Familiar With Emerson’s Electronic Marshalling Controllers Various busses Wireless I/O Electronic Marshalling
  • Electronic Marshalling Structure & Definitions
    • Fast Facts
      • Electronic Marshalled I/O
    • Types
      • CHARMS available today
        • AI 4-20 mA HART
        • AO 4-20 mA HART
        • DI NAMUR
        • DI 24 VDC Low Side
        • DO 24 VDC High Side
        • Thermocouple/mV
        • RTD
        • Voltage 0-10 VDC
    • Rules
      • 8 Base Plates per CIOC
      • 12 Terminal Blocks per Base Plate
      • 96 CHARMS per CIOC
      • Install in Div 2 or Zone 2
    CHARMS CIOC Carrier CIOC (Redundant) Terminal Block Base Plate CHARM Electronic Marshalling
  • Background on Hazardous Locations An area containing (or likely to contain) an ignitable concentration of flammable gas or vapor, where an electrical spark of sufficient power will cause an explosion. HAZARDOUS NOT HAZARDOUS
  • Hazardous Location Explosion Triangle
    • All three must be present to cause an ignition
    • Basis for most protection methods
    • Eliminate one and the operation is safe
    Oxidizer Fuel (Air) (Gas, Vapor or Dust) Energy (Thermal or Electrical) E x
  • Hazardous Locations & Protection – Examples Class I ; Division 1 ; Groups A,B,C,D ; T6 Permitted Class Permitted Division Gas Groups Temperature Class Zone 1 , Ex ib IIB T6 Gas Groups Temperature Class Type(s) of Protection Permitted Zone Defined by FM & ANSI/ISA Defined by IEC & CENELEC Traditionally Zones have been in Europe Traditionally Divisions have been in the US
  • Intrinsic Safety – Methods of Protection
    • Methods of protection in hazardous environments
      • Containment, e.g. Explosion Proof, Ex d
        • Contains an explosion (at the electronics) within an enclosure or housing; prevents the explosion from propagating outside the enclosure to the process area
      • Segregation, e.g. Purge/Pressurization, Ex p
        • Prevents the Oxidizer and Fuel from coming into contact with the electronics
      • Prevention, e.g. Intrinsic Safety, Ex i (e.g. Ex ia, Ex ib, Ex ic)
        • Prevents the Energy at the electronics from being high enough to cause an explosion
    • Intrinsic Safe ty has emerged as the preferred method of protection in most world areas
  • Protection Methods
  • Comparison of Protection Methods
  • Intrinsic Safety: Basic Concept An intrinsically safe circuit consists of the following: - Intrinsically Safe Equipment - Interconnecting Wire - Associated Apparatus Intrinsically Safe Equipment Associated Apparatus Associated Apparatus
  • Ignition Curves
    • Intrinsically safe circuits operate below the minimum ignition point during normal and abnormal operation with a 50% safety factor
    • Relevant standards
      • UL913
      • FM3610
      • CSA C22.2 No. 157
      • ISA 12.2.01
      • IEC 60079-11
  • Explosion Prevention Via Intrinsic Safety
    • Intrinsic Safety “ i ”, example Ex ia
      • Divisions 1, 2 / Zones 0, 1, 2
    • Intrinsic Safety Characteristics
      • A low power technique is used to limit voltage, current, and stored energy to a level below the minimum required for ignition during both normal AND abnormal operation of the equipment under consideration.
    Hazardous Area V R L C Isc/Io 3x Voc/Uo Barrier Cable + -
  • When to use Intrinsic Safety
    • Intrinsic Safety circuits are used when field devices are located in hazardous environments; they protect the circuit by limiting the energy to the field devices.
    • Field devices can be located in hazardous environments that are rated
      • Zone 0, Zone 1, or Zone 2
      • Class I Division 1 or Class 1 Division 2
    • Protection levels for the circuits could be
      • Ex ia, Ex ib, or Ex ic
    • Circuits will have defined parameters for Voltage, Current, Power, Capacitance, and Inductance
  • When IS is not a Good Fit...
    • Some plants are geographically dispersed meaning that the presence of explosive hazards for any period of time is unlikely.
    • Some plants do not have the possibility of explosive mixtures being present
    • If your customer already uses Explosive Proof methods, they are unlikely to adopt IS in the same facility
    • In North America, IS is not typically used.
      • This is changing slowly. Some US plants with IS include
        • 3M
        • Bayer
        • BASF
  • Intrinsic Safety Protection
    • Lower initial cost
    • Conduit not required; poured seals not required
    • Any suitable enclosure is acceptable in Div 2
    • Reduced cost of ownership (maintenance, calibration, repair)
    • Use of simple apparatus offers flexibility
    • Suitable for all gasses
    • Permits live maintenance; lowers cost and increases safety
    • Accepted globally
    • Can only be used for low power
    • Cable parameters must be considered for IS applications in loop proofing
    • Perceived to be complex
    Advantages Disadvantages
  • Intrinsic Safety Applications NOTE: For Hazardous Environment applications, Intrinsic Safety is easier to understand and easier to apply; however, where Intrinsic Safety methods of protection will be applied, be sure that you have the proper experience, and please contact Pepperl+Fuchs or Emerson Intrinsic Safety experts NOTE: Intrinsic Safety training and education is recommended and can be made available to you, please contact Pepperl+Fuchs or Emerson Intrinsic Safety experts
  • How to Achieve Intrinsic Safety with DeltaV
    • Numerous Options & Applications with Emerson DeltaV
    • Traditional DeltaV I/O and external Pepperl+Fuchs IS modules
      • M-Series
      • S-Series
      • Emerson Standard CHARMS I/O
    • Emerson IS CHARMS
    • DeltaV SIS and external Pepperl+Fuchs IS modules
    Via energy limiting devices, IS barriers, that limit energy in the circuit…
  • Intrinsic Safety “Apparatus” – Traditional
    • Associated Apparatus provides the protection
    • Intrinsic Safety Approved Apparatus are the field devices
    Approved Apparatus Connecting Cable Associated Apparatus DCS, e.g. DeltaV Hazardous Area Approval Focus Area
  • Intrinsic Safety “Apparatus” – IS CHARMS
    • Associated Apparatus provides the protection
    • Intrinsic Safety Approved Apparatus are the field devices
    Approved Apparatus Connecting Cable Associated Apparatus DCS, e.g. DeltaV More details later in presentation!! Hazardous Area Approval Focus Area
  • How to Achieve Intrinsic Safety with DeltaV
    • IS barriers can be external isolators
    • IS barriers can be embedded with DCS I/O as in the case of IS CHARMS
    Via energy limiting devices, IS barriers, that limit energy in the circuit… External IS Barriers IS CHARMS Traditional IS modules from Pepperl+Fuchs IS CHARMS from Emerson inside
  • External P+F IS Isolating Barriers
    • Only a few channels of IS needed
        • OR
    • Customer preference for redundant, multi-channel traditional I/O cards in S-series
        • OR
    • DetlaV SIS requires external IS barriers
        • OR
    • Customer preference for external IS barriers due to experience, spares, standard operating practice, etc.
        • OR
    • Emerson has opted to sell M-series or Ovation to the customer
    Via energy limiting devices, IS barriers, that limit energy in the circuit… Adding External IS Isolating Barriers to DeltaV or DeltaV SIS DeltaV S-series Hazardous Area
  • Intrinsic Safety with Traditional I/O DeltaV M-series DeltaV S-series Via energy limiting devices, IS barriers, that limit energy in the circuit… Adding External IS Isolating Barriers to DeltaV or DeltaV SIS Hazardous Area Hazardous Area
  • Intrinsic Safety with Traditional I/O Via energy limiting devices, IS barriers, that limit energy in the circuit… Many wires!! Too much cabinet space DeltaV S-series Hazardous Area
  • Intrinsic Safety with Standard CHARMS I/O Via energy limiting devices, IS barriers, that limit energy in the circuit… CHARMS DeltaV S-series External IS Barriers Cables, labels, associated drawings, and installation/checkout in FAT can cost more than DCS I/O channel hardware or an external IS barrier/isolator. Hazardous Area
  • Intrinsic Safety with Standard CHARMS I/O Via energy limiting devices, IS barriers, that limit energy in the circuit… CHARMS DeltaV S-series External IS Barriers Cables, labels, associated drawings, and installation/checkout in FAT can cost more than DCS I/O channel hardware or an external IS barrier/isolator. Hazardous Area
  • Now IS CHARMs are Available Controllers Various busses Wireless I/O Electronic Marshalling
  • Intrinsic Safety & Emerson IS CHARMS
    • Makes it EASY!!
    • Combines Emerson I/O CHARMS and Pepperl+Fuchs Intrinsic Safety Barrier technologies into a single, small, integrated package … IS CHARMS
    • Associated Apparatus
    inside
  • IS CHARMS – Integrated I/O & IS Protection
    • Fast Facts
      • I/O plus IS protection
      • IS protection plus galvanic isolation
    • Types
      • IS CHARMS available 4Q 2011
        • AI 4-20 mA HART
        • AO 4-20 mA HART
        • DI NAMUR
        • DO 11V @45mA VDC High Side
      • IS CHARMs available 3Q 2012
        • Thermocouple/mV
        • RTD
    • Rules
      • 8 Base Plates per CIOC
      • 12 Terminal Blocks per Base Plate
      • 96 IS CHARMS per CIOC
      • Install in Div 2 or Zone 2
      • Can mix Standard CHARMS Base Plates with IS CHARMS Base Plates
    IS CHARMS CIOC Carrier CIOC (Redundant) IS Terminal Block IS Base Plate IS CHARM inside
  • Intrinsic Safety with IS CHARMS I/O Via energy limiting devices, IS barriers, that limit energy in the circuit… IS barriers built into IS CHARMS!! IS CHARMS
    • Smaller Footprint
    • Less Design
    • Lower Project Costs
    • Long Term Benefits
    • Emerson Unique
    DeltaV S-series IS CHARMS replaces many wires with 2 wires! Hazardous Area
  • Why the IS CHARMS Solution?
    • Project Benefits
      • Smaller cabinet footprint, than external IS barriers
      • Less Design
      • Fewer cabinets; smaller cabinets
      • Fewer drawings
      • Fewer wires to connect and label
      • Easy last minute project changes
      • Lowest Total Installed Cost
    • Long Term Customer Benefits
      • One warranty. One company responsible.
      • Falls under standard Emerson life cycle plan
      • Fewer points of failure (screw terminal reduction)
      • Highest availability with single point integrity
      • Fewer spares
      • Less maintenance and inspection requirements
      • Higher safety and availability
    • Emerson is unique in this offering; others cannot compete
  • IS CHARMS Replace IS Barriers IS CHARMS 120 I/O CONVENTIONAL IS BARRIERS 120 I/O
  • Cost Comparison – Business Results Achieved IS CHARMS CONVENTIONAL IS BARRIERS
  • Intrinsic Safety with DeltaV SIS I/O DeltaV SIS DeltaV S- or M-series Via energy limiting devices, IS barriers, that limit energy in the circuit… Adding External IS Isolating Barriers to DeltaV or DeltaV SIS BPCS Hazardous Area SIS Hazardous Area
  • Summary
    • Discussed Intrinsic Safety Basics
    • Discussed Application of the Intrinsically Safe CHARMS Modules for Project Savings
    • Use of IS CHARMS reduces project cost and improves safety
    • Questions??
  • Where To Get More Information
    • Attend Short Course Session ID: 4-2391 “Intrinsic Safety Fundamentals & IS CHARMS”
    • Attend Emerson DeltaV Roadmap
    • Visit us in the exhibition hall for a live demos
    www.pepperl-fuchs.us Order a Free: Pepperl+Fuchs Interface Technology Engineer’s Guide [email_address]