Mechanical integrity ... safety in the design phase ... safety in the manufactory phase ... safety in the field operation phase Actor: Alain Engels (Endress+Hauser)

1. 23/04/2015
Products Solutions Services
Safety by Design
Mechanical integrity ………. safety in the design phase
………. safety in the manufacturing phase
………. safety in the field operation phase
Leading Technologies and Services
for a Safe Plant Operation
Slide 1 Alain ENGELS

2. 23/04/2015
Safety BY DESIGN – A life time commitment
• Endress+Hauser design standards
• Material selection
• Design simulations using “Finite Element Methods”
• Mechanical design stress testing
• Welding Procedure Specifications
• Sealing concepts
• Inherently safer designs
Mechanical integrity ……….safety in the design phase
Slide 2 Alain ENGELS

3. 23/04/2015
Endress+Hauser design standards
Slide 3
• Design and testing experience
built on generations of product
history within Endress+Hauser ,
Endress+Hauser customers and
industry/academic organizations
• Costly and unproductive
complexity is avoided by
standardized development across
all Endress+Hauser operations
• These standards help
Endress+Hauser reduce risk in the
design, manufacturing and
documentation of products, in turn
helping us reducing risks to our
customers
Alain ENGELS

4. 23/04/2015
Material selection
 Metals
• The selection of the correct type and form of metals used within
an instrument is built on years of experience and testing.
 Plastics/elastomers
• A wide variety of non metallic polymer materials are available
for seals, containment, insulation, etc
 Glass/ceramics
• Non-metallic materials such as glasses, graphite, ceramics are
typically selected for seals, insulation, etc. for demanding
service especially under higher temperatures and pressures
 Heterogeneous assemblies
• Assemblies with combinations of materials can have complex
interactions that must be suitable for the design service.
• Understanding how the combination of forms and compositions
will behave are critical to achieving a low risk service design.
Slide 4
Advanced ceramics &
graphite in high
temperature process
seals
Alain ENGELS

5. 23/04/2015
Design Simulations
 Endress+Hauser uses the latest design FEA tools to
simulate real world effects (i.e. fatigue, failure) on
designs from mechanical forces, heat, vibration, fluid
flow and other physical stresses to reduce risk.
stress
strain
elastic area
yield strength
Slide 5 Alain ENGELS
Finite Element Methods

6. 23/04/2015
Stress testing
 Vibration testing
• Testing of prototype components or final products to ensure the final
design will provide expected resistance
• Amplitude and frequencies (g forces) are varied in X, Y and Z directions
 Shock testing
• Subjecting components or final products to abrupt forces or strikes to
test integrity as specified
 Fatigue testing
• Some components in a design subjected to mechanical movement over
time may develop weaknesses leading to failure
• Repetitive flexing or mechanical movement may be conducted over a
period of time to ensure the right material for the design is used
 Burst testing
• Testing is conducted on a component or final product to pinpoint the
level at which function or containment is lost
Slide 6 Alain ENGELS

7. 23/04/2015
Welding procedure specifications
 Welding Procedure Specifications (WPQR & WPS) are managed
according to required standards
 Clear and transparent guidelines prevent defective work in
manufacturing and customer documentation.
Slide 7 Alain ENGELS

8. 23/04/2015
Sealing concepts
 Instruments by their nature are often installed in
hazardous areas, inserted into extreme process pressures,
temperatures and exposed to all types of materials
 An instrument needs to be robust enough to avoid a
release of process material or needs to be predictable in
how it releases process material so risk is managed
 Showing a customer the complexity in a cross section
picture or model of some of our instruments may help
them grasp there is more mechanical design built in than
what appears from the outside
Slide 8
Advanced ceramics –
graphite process seals
for high pressure and
extreme temperatures
Advanced metallic
spring loaded PTFE
sealing concept.
Alain ENGELS

9. 23/04/2015
Inherently “Safer” designs
 Non intrusive measurement technologies
• No mechanical impairment of the process equipment by using non-
intrusive / non-invasive instrument designs
• Radiometric level and density measurements
• Ultrasonic Clamp on flow measurement
• Skin point temperature measurements
 Mechanical assemblies with predictable failure modes
Rupture
Disk holder
Predetermined breaking point
Slide 9
Annunciation
Opening behind
second line of
defense
Alain ENGELS

10. 23/04/2015
Safety BY DESIGN – A life time commitment
• Manufacturing quality assurance
• Material traceability
• Positive Material Identification (PMI)
testing
• Radiographic (RT) testing
• Dye penetrant (DPI) testing
• Welding Procedure Qualification Reports
• Hydrostatic pressure testing
• Helium leakage testing
Mechanical integrity ... Safety in the manufacturing phase
Slide 10 Alain ENGELS

11. 23/04/2015
Manufacturing quality assurance
• The quality assurance systems at Endress+Hauser are based on ISO
defined criteria and are regularly audited by outside agencies.
• ISO 9001 Quality Management System
• ISO 14001 Environmental Management System
• OHSAS 18001Occupational Health and Safety Management System
• Each employee in our organization shares the responsibility for
consistently producing the products expected by our customers
• Dedication to quality and continuous quality improvement is cultural
at Endress+Hauser….and our safety message as well!
Reference resources slide for more information and access
Slide 11 Alain ENGELS

12. 23/04/2015
Material traceability
• Maintaining absolute material identification, inventory and
traceability from incoming stock to finished delivered product and
documentation is a core strength of Endress+Hauser manufacturing.
• Material traceability and sometimes proof of traceability is required
by process plant engineering and construction operations to ensure
predictable containment integrity
Slide 12 Alain ENGELS

13. 23/04/2015
Positive Material Identification (PMI)
• Endress+Hauser uses PMI testing as a non-destructive method which does not
affect the material properties. It is not a substitute for a traceability certificate
• PMI testing is performed by emitting X-rays on the material to be tested, which
then responds by sending out XRF (X-ray fluorescence) signals of varying energy
and intensity depending on its chemical composition. The XRF signals are then
recorded by an XRF analyze
• Studies show that in Petrochemical and Refinery facilities almost half of the
largest losses are a direct result of failures in piping systems. PMI testing is
commonly used method to eliminate any material mixing errors
Slide 13 Alain ENGELS

14. 23/04/2015
Radiographic (RT) testing
• Endress+Hauser uses industrial radiography or
X-ray testing to inspect materials for hidden flaws
to reduce risk
• Reveals material defects (visible as well as hidden)
on metallic materials .
• Especially well suited for welding seam analysis
since even very small defects can be identified.
• Non-destructive as it does not affect the material
properties or leave any marks on the measured
surface.
• Report generated by qualified Endress+Hauser
personnel is included with the instrument
documentation when specified
Slide 14 Alain ENGELS

15. 23/04/2015
Dye penetration (DPI) testing
• Dye Penetrant Inspection (DPI), also called Liquid Penetrant
Inspection (LPI) or Penetrant Testing (PT), is used by
Endress+Hauser to locate surface-breaking defects in all non-porous
materials
• LPI is used to detect casting, forging and welding surface defects such
as hairline cracks, surface porosity, leaks in new products, and
fatigue cracks on components
Slide 15 Alain ENGELS

16. 23/04/2015
Welding procedure qualification
• Welding seams on many Endress+Hauser products are produced by automatic
welding machines according to instrument specific WPQR/WPS (Welding
Procedure Qualification Record/Welding Procedure Specification) and
supervised/controlled by approved welding engineers.
• Frequent inspection of both welding machines and the resulting welding seams are
conducted to maintain the highest quality demands and regulatory requirements.
• Customers can fully rely on the welding seam quality of any Endress+Hauser
welded device
Slide 16 Alain ENGELS

17. 23/04/2015
Hydrostatic pressure testing
• Hydrostatic testing is a safer way to verify the integrity of a
manufactured instrumentation component that is designed for
pressure service.
• Many Endress+Hauser components are 100% tested while others are
tested to meet specific customer or industry requirements
Slide 17 Alain ENGELS

18. 23/04/2015
Helium leakage testing
• Leak testing is part of the
Endress+Hauser non-
destructive test NDT portfolio
that can be applied to a
fabricated component to verify
it is leak proof
• For example, Liquiphant
extensions are 100% Helium
tested to ensure component
welding is fully accomplished
and there are no leak points
Slide 18 Alain ENGELS

19. 23/04/2015
Safety DURING OPERATIONS – A life time commitment
• Examples of Endress+Hauser
Mechanical Integrity in field
operations
 Mechanical integrity diagnostics
 Inherently safer components
 Process containment
Mechanical integrity ………. Safety in the field operation phase
Slide 19 Alain ENGELS

20. 23/04/2015
Examples of mechanical integrity in field operations
Levelflex
level
Liquiphant
Soliphant
levelswitch
Cerabar/
Deltabar
pressure
Prowirl
Vortex
flow
iTHERM®
StrongSens
temperature
Memosens
Analytical
Promass
Coriolis
Mass flow
Engineered
Temperature
Slide 20 Alain ENGELS

21. 23/04/2015
Liquiphant - Engineering at a glance
Special Features:
• operating temperatures -60 to
280 °C ( -75 to 535°F) (300°C
(570°F) for max. 50 h cumulated)
• pressures up to 100 bar ( 1450 psi)
• highly corrosion resistant material
Alloy C22 (2.4602)
• Including welded-in gas tight feed-
through (second line of defense)
FTL7x
electronic-
insert
Welded gas
tight feed-
through
(second line of
defense)
temperature
spacer part
Ex d -
thread
Piezo-stack drive
vibrating fork
Alain ENGELSSlide 21
The gas tight feed-through prevents e.g. leakage of toxic media
Highest Safety Even in Case of Damaged Sensor

22. 23/04/2015
Soliphant M – engineering at a glance
Improved housing
 Smaller
 More vibration resistant
through new clamping disk
 New seal for F15
Dip switches for
selection of:
 Sensitivity
 Switching delay
 Min/Max function
 Diagnosis
Climate seal
NAMUR electronics
New threaded drive
 Welding seam is eliminated
 Smaller and stronger
316L sensor material
 No material mix
 Optional abrasive
resistant coatings
2 fork types
 Short fork for small tanks
 1¼“ NPT diaphragm
Save sensor circuit
SIL 2
Gas-tight feedthrough for
Ex d/de (FTM51, FTM52)
New fork geometry
 Stronger root
Slide 22 Alain ENGELS

23. 23/04/2015
Cerabar S/Deltabar S - Secondary Containment
Ceramic Sensor
• gas tight containment to 120 bar (1740 psi)
• diagnostics in DP cell advising of membrane
rupture
Metal Sensor
• pressurized containment (gas tight
feed through, 400 bar (5800 psi) proven)
• completely welded membrane, no seals
Cerabar S
Deltabar S
Differential pressure Sensor
• containment to 1050 bar (15225 psi)
• function control
• withstands alternating loads
Alain ENGELSSlide 23
The gas-tight feed through prevents leakage of medium in case of failure
Highest safety by second process barrier

24. 23/04/2015
Levelflex – FMP54 – Heavy duty under harsh conditions
FMP54
Special Features:
• Robust design and gas tight glass feed-
through
• -196 to +450 °C (-320 to 840 °F)
• Pressures up to 400 bar (5800 psi)
• High diffusion resistance using
ceramic coupling and graphite seal
• Resistant against Superheated steam
(ceramic seal) – application in steam
boilers acc. to EN12952/12953 (NM,
HW, Range)
• Finite element simulations
graphite
2nd process
containment
(gas tight glass feed-
through)
ceramic
Alain ENGELSSlide 24
The gas tight feed-through prevents e.g. leakage of toxic media
Highest Safety at High Pressure and High Temperature

25. 23/04/2015
Proline Prowirl – The reliable multi talent body
Application
example:
Loading of liquid
nitrogen at
-196°C/-320°F
Special features:
 Extremely robust basic body
design
 Temperatures -200 to 400°C
(-325 to 750°F) (optional
450°C (840°F))
 Pressure levels up to PN250/
ANSI 1500 lb
 Material stainless steel
(standard), Alloy C-22 (e.g.
corrosive applications)
Proline Prowirl
Shrunk and welded-
in bluff body ensures
safety during steam
hammers
Alain ENGELSSlide 25
High reliability and high life time even under extreme process conditions
(pressure, temperature)

26. 23/04/2015
Proline Prowirl – the reliable multi-talent sensor
Special Features:
• Robust and unique DCS-Sensor
technology
• No aging or wear
• Insensitive versus water hammers
• Highest vibration resistance
(1g at 10…500Hz)
• Insensitive versus temperature shocks
(150K/s)
• Second containment
• Flow rate up to 120m/s (393 fps)
• Proven in use – above 250.000
installed Sensors
DCS = Differential Capacitance Sensor
Gas tight
Glass feed-through
Alain ENGELSSlide 26
Unique DSC-Sensor technology with second containment
High Reliability, Safety and Long Term Stability
containment
HP version
up to 160Bar

27. 23/04/2015
Promass E200/F200 – Two wire-Coriolis-mass meter
Special Features:
• robust housing offers maximum
operation safety in harsh environment
• industrial standards and requirements
consistently realized
Promass E 200 – Standard device lay
length according to NE132 (NAMUR)
Promass F 200 – the market leader in
two wire technology
Alain ENGELSSlide 27
Increases safety and reduces costs for planning, procurement and operation
max. safety with standardized two wire concept

28. 23/04/2015
Memosens is safe in all aspects
Memosens simplifies the operation
• Simply connect the sensors and they deliver reliable values immediately.
• Calibrate the sensors in the lab and exchange them on site in no time.
Memosens increases plant safety
• The inductive plug-in head eliminates all problems due to moisture.
• Digital transmission displays errors actively and enables you to react immediately.
• Simply exchanging the sensors in the field increases availability of measuring point.
Forms the basis for the first certified SIL 2 analytical measurement platform
 Highest measuring safety and minimized risk for maintenance staff
inductive signal transfer
inductive energy supply
pH/ORP Oxygen Conductivity Chlorine
Slide 28 Alain ENGELS

29. 23/04/2015
Retractable holder–safe port to process for liquid analysis
Cleanfit CPA450 with service friendly safety
locking device:
• holds max pressure up to 12 bar ( 170 psi)
• avoids opening the retractable under
process pressure
Enhanced safety in the insertion position
• lock ring and
• safety locking device made from 316L
Cleanfit CPA472D with safe blocking system:
• No pneumatic positioning in process if a
sensor is not installed
Slide 29 Alain ENGELS

30. 23/04/2015
iTHERM® StrongSens
Robust thermometer with thin film sensor
Special features:
• Robust Pt100 metering sensor with high
vibration resistance for temperatures up to
500°C (60g)
• Robust verified and “calculated” design
Alain ENGELSSlide 30
Unique sensor technology for demanding applications
Longest life time with optimized operation safety

31. 23/04/2015
Thermowell Calculation
 Verification of the mechanical strength of a
thermowell for the individual process
conditions.
 Calculation according to DIN 43772 or
ASME/ANSI PTC 19.3
Is the thermowell able to withstand the process
conditions?
 Static process pressure
 Dynamic flow pressure
 Flow induced vibrations
 Strength of material at process temperature
Slide 31 Alain ENGELS

32. 23/04/2015
Temperature Engineered Solution
Diagnostic and containment chamber –
second sealing barrier
Individual
thermowells –
first sealing
barrier
Connections for diagnostic chamber monitoring
Multipoint with Dual-sealing barriers
Special features:
• Highest plant safety due to dual
sealing barriers
• Safe diagnostic chamber monitoring
under pressure ensures continuous
plant operation
• Replaceable sensing elements
ensures continuous plant operation
• Advanced diagnostics capabilities
Alain ENGELSSlide 32
Dual seal and diagnostic functions ensure …
Safe plant operation in high risk environment

33. 23/04/2015Slide 33
Temperature Engineered Solution– Multipoint TM911
 Unmatched safety concept with up to 3 barriers
 Safe operation also in fault condition (leakage)
 No unplanned shut downs!
Alain ENGELS

34. 23/04/2015
Mechanical integrity planning
• Endress+Hauser provide tools to take risk out of specifying the right
mechanical components for specific service
• Endress+Hauser trained personnel and customers who have the
experience or Endress+Hauser training rely on these tools
Alain ENGELSSlide 34
Applicator
&
Selection Guides

35. 23/04/2015
Products Solutions Services
Any Questions?
Alain ENGELSSlide 35

36. 23/04/2015
Products Solutions Services
Thank you very much
for your attention
Alain ENGELSSlide 36