FEATURE FLOW & LEVEL CONTROL VERIFYING METERS IN A HEARTBEAT


process parameters, all of the important information needed to optimise maintenance and processes is available at a glance. Similarly, food and beverage


Endress+Hauser describes the benefits of its Heartbeat Technology, which is incorporated in a range of its measurement devices. A combination of diagnostics, verification and monitoring, the technology helps ensure safe and cost-efficient plant operation


hemical plants operate under tough conditions, often running at full capacity to ensure cost-effective operation. The aim is to keep the plant up and running for as long as possible in between the necessary inspections. For this to happen, measuring points must function reliably. When it comes to replacing products or media such as steam and water between production runs, it is also essential that the measuring points used for billing purposes are accurate. Regular function checks on measuring


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points are therefore indispensable. In most cases, these take place when the plant is already out of operation due to an inspection. However, maintenance cycles also mean longer periods of downtime, resulting in loss of earnings. Service and maintenance are an


important part of a plant operator’s duties. It is of particular importance that the verifications performed and the reliable operation of measuring points are documented.


MEASURING POINTS There is clearly a demand for measuring points that are reliable and also easy to use and maintain. The device status must be easy to identify at all times, and documentation must be kept as straightforward as possible. Thanks to Heartbeat Technology, you


can check measuring points while they are installed and while processes and measurements continue to run.


32 MAY 2017 | PROCESS & CONTROL


Verifications can be performed on site, but can also be done safely from the comfort of the control room. Even the documentation is simple thanks to asset management software (DTM) that generates and maintains a PDF document in each case.


COMPLETE FLEXIBILITY As Heartbeat Technology can be used during operation, the operator is able to maintain complete flexibility when it comes to scheduling a measuring point inspection. The verification itself seldom takes more than a minute, and the time saved from when a connection is established to when the documentation is completed is generally in the region of 80% compared with verifications using external verification and inspection equipment (such as Fieldcheck). This verification is performed at no additional cost, making it suitable for use in new situations for the purpose of documenting the fault-free status of devices, following calibration or repair for example. In addition, increased safety is achieved


with less effort than before. Even the guided SIL proof test in accordance with the safety manual and documentation saves time and reduces costs. An automatically generated verification protocol provides the evidence necessary to comply with regulations, laws or factory standards. Heartbeat Technology can also be used to perform a trend analysis for predictive maintenance. Using a combination of device and


Heartbeat Technology offers users the ability to increase plant availability and decrease costs


manufacturers operate in accordance with strict guidelines. For a start, there are the intensive inspections that are part and parcel of Good Manufacturing Practices (GMP), and there are usually requirements to be met for ISO 9001 recertification too. Food authorities require that manufacturing processes including measuring technology undergo a validation process. If you wish to make a change to a process, the cost is significant and a revalidation is required. Nevertheless, intense competitive pressure forces manufacturers to follow through with each potential process optimisation. Each type of measuring equipment must be calibrated or verified regularly in accordance with ISO 9001:2008 Clause 7.6a. Here the operator must comply with the rules of metrologically traceable verification in order to avoid delays and costly adjustments during the recertification process.


VERIFY WITHOUT INTERRUPTION The calibration of process instruments usually involves considerable resources and often poses a risk to hygiene. An ideal solution is to verify devices without interrupting the process, reducing risk and saving both time and money. Using Heartbeat Technology, measuring


Savings in the chemical industry:


• Time saving of 1.5 hours per verification = €150 per verification. The additional cost of the Heartbeat option is recouped after just the third verification


• Calibration is required only every 4–5 years instead of annually. The savings per device range from €500–€1,000 per verification. The cost is recouped once the first calibration is dispensed with


• Guarantee of significantly higher returns due to plant availability


points can be verified in situ and without any interruption to measurements or processes. As described, with Heartbeat Technology, the operator maintains flexibility when it comes to scheduling a measuring point inspection, as there is little effort involved and it can be performed while the plant is in operation. Extended calibration cycles result in


additional savings in maintenance costs and increased plant availability: calibration is required only every two to three years instead of annually. Not just regulatory authorities but operators too welcome the fact that hygienic piping does not need to be opened up as often, thus improving product safety. Thanks to Heartbeat Technology, you can avoid unnecessary process interruptions, meet your documentation obligations more easily and increase product safety.


Endress+Hauser www.uk.endress.com


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