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
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Safety Instrumented SystemSafety Instrumented System

3. KPIsKPIsKPIsKPIs
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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
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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
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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.
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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
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(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
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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
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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
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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
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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
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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
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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:
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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
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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
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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
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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
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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
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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
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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.
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TraceTek Sensor Cable

25. Leak Detection – Meeting RegulationsLeak Detection – Meeting Regulations
Increasing Regulations for storage tanks
Alaska CaliforniaAlaska California
Florida & others
Other
Countries
Globally
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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
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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
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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
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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
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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
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31. ً‫ا‬ ‫شك‬ً‫ا‬ ‫شك‬‫ا‬‫ر‬‫شك‬‫ا‬‫ر‬‫شك‬
ThankThankThankThank
YouYou
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