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And what’s happening in the field?

In keeping with tradition, the Namur Award was presented to Michelle Blumenstein from Helmut Schmidt University Hamburg, at the start of the second day of the Namur Main Session. Her work dealt with connecting two seemingly different worlds using the example of the Open Process Automation standard from the oil/gas industry and VDI/VDE/Namur 2658, which had its beginnings in specialty chemicals.

But now, let's move on to sensors, more specifically M+O (Monitoring + Optimization) sensors. “The term M+O is coming up more and more often, but for many, it is still somewhat vague,” explains Thomas Mayer from BASF. These sensors are a central building block of the NOA (Namur Open Architecture) and enable new applications in the digitization of production plants. The goal is to obtain additional information and process it — independently of the core automation. “At M+O, we are in a parallel world,” Mayer affirmed.

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This involves the simple integration of Industry 4.0 applications with additional sensor technology, e.g., to make production processes more transparent and efficient. Applications include monitoring new components, the integration of temporary measurements via clamp-on, or monitoring buildings, electrical systems, and assets, such as the tracking of containers. Already proven in practice is, for example, the anomaly detection of heat exchangers via models or the predictive detection of motor damage on pumps with vibration sensors. Reducing walkarounds by integrating wireless pressure gauges into the sensor landscape or position feedback from manual valves via radio are also compelling use cases.

“However, we have a new type of sensor here that is different from the M+C sensors,” affirmed Leonore-Sophie Keil from BASF. “The revised Namur Recommendation 183 should therefore be a guide for users and manufacturers.”

Alternative ways in the selection of field devices for process control safety devices

Device safety was the focus of NE 130, which is also currently under revision. In safety devices, systematic faults predominate and must be controlled. This is done by using operationally proven devices, increased redundancy, and with devices certified to IEC 61508. Random faults are eliminated by SIL calculations or by avoiding too much complexity. In particular, operational verification significantly contributes to safety, as it provides evidence of freedom from systematic faults.

The challenge for users is that IEC 61511-1 only contains basic requirements on the subject of operational reliability. Therefore, NE 130 is currently being revised and serves as an aid for the user. It is supplemented by IEC 61508 and VDI Guideline 2180. “Together, there is a lot of room for interpretation for each user,” according to the practical experience of Hayriye Yazici, Bayer. Above all, it shows alternative ways.

Prior Use in accordance with IEC 61511 can be selected, for example, if the classic route does not work, but the device is put through its paces in practice. The prerequisite is ten devices that have been in operation for at least one year and more than 100,000 operating hours. The background is that not every site has resources for type testing in the laboratory.

Another alternative, if it is not possible to carry out operational validation according to the Namur concept or the Prio Use according to 61511, is device development according to DIN EN 61508. Here, certification is carried out by an independent, recognized external test center. In addition, application-specific operational approval should also be possible in individual cases, as should special approvals. This applies, for example, to type-tested components or valves that are not certified in accordance with the Pressure Equipment Directive. However, such approval is not equivalent to operational probation but applies only to a specific application. “A generalization is not possible,” Yazici emphasized.

Systematically recording faults

The topic of functional safety continues to drive the industry. Twenty years ago, they started with fault data acquisition as part of NE 93, and for the past five years, they have been on the road with the Namur. smart tool. “The tool collects data according to NE 93, and it now includes more than 100,000 PCE devices with safety functions and more than 250,000 devices. Fault recording is increasing across the board,” Dirk Hablawetz, BASF, reported on the tool's success. In it, faults are recorded in safety functions and devices. The aim is to identify fault patterns, weak points in devices in various applications, and functional safety management. The optimal test cycles can be defined or the service life derived from this. This is also important in terms of inventory protection.

Of particular interest: this can be used to develop KPIs that can provide an indicator of equipment reliability. The devices installed in PLT safety equipment generally work very reliably. There is a need to avoid systematic errors, i.e., the handling of the devices. “Qualification and training are important points here that we will have to deal with more closely in the future. Because experience shows: The proportion of errors on the equipment is lower than the proportion of errors related to handling. In addition, error analysis in the actuator technology shows that the more electronics come into play here, the more frequently random errors occur. This applies all the more as the equipment becomes more complex,” says Hablawetz.

Robots in chemical plants?

Speaking of new approaches: On day 2 of the Namur Main Meeting in 2021, the Open Innovation Challenge “Production Service Robots for Chemical Plants and Sites.” Carl-Helmut Coulon from Invite presented the competition, which is under the auspices of Namur. In the future, robots will take over regular inspections and other tasks in chemical production plants. The systems must prove their mettle in a 36-m² environment. The robots must navigate, collect data, perform simple manipulations and provide transportation. To that end, BASF, Bayer, Boehringer, Merck, and Wacker are looking for teams from around the world to show the world how close their technology is to that vision over the next 12 months.

The project partners will select six applicants to present their technology at Achema 2022 and in a final competition in the fourth quarter of 2022. A total of 105,000 euros in prize money will be awarded to the participating teams.

The initiators agree that it would be desirable to have a robot perform inspection tasks around the clock throughout the plant and draw samples automatically. Against this at the moment are the economics, although the technology is available. “So, we are looking for an economical solution that is modular, flexible, and scalable,” Coulon said, describing the requirements. The finalists are expected to present themselves in Hall 11 at Achema as early as April 2022.

There is sure to be a glimpse at the upcoming Namur main meeting, held under the motto “Sustainable Lifecycle Risk Management” and sponsored by Hima. Namur will meet again in Düsseldorf/Neuss on November 10/11, 2022.

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