User's
Manual
ROTA
Coriolis Mass Flow and Density Meter
MASS
Total Insight
Safety Manual
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Table of contents
Table of contents
1 Scope and purpose of the document ...................................................................................................... 3
2 Using Rotamass Total Insight for a SIS application .............................................................................. 4
2.1 Safety function .................................................................................................................................. 4
2.2 Safety accuracy ................................................................................................................................ 5
2.3 Diagnostic response time ................................................................................................................. 5
2.4 Setup ................................................................................................................................................ 5
2.5 Proof testing...................................................................................................................................... 5
2.6 Repair and replacement ................................................................................................................... 6
2.7 Startup time ...................................................................................................................................... 6
2.8 Firmware update............................................................................................................................... 6
2.9 Reliability data .................................................................................................................................. 6
2.10 Lifetime limits .................................................................................................................................... 7
2.11 Required parameter settings ............................................................................................................ 7
2.12 Environmental limits.......................................................................................................................... 7
2.13 Application limits ............................................................................................................................... 7
3 Definitions and abbreviations .................................................................................................................. 8
3.1 Definitions ......................................................................................................................................... 8
3.2 Abbreviations .................................................................................................................................... 9
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Scope and purpose of the document
1 Scope and purpose of the document
When using the Rotamass Total Insight Coriolis flow meter for the Safety Instrumented
Systems (SIS) application, the instructions and procedures in this section must be strictly
followed in order to preserve the transmitter for that safety level.
This document provides an overview of the user responsibilities for installation and operation of the Rotamass Total Insight Coriolis flow meter in order to maintain the designed
safety level.
Items that will be addressed are proof testing, repair and replacement of the flow meter,
reliability data, lifetime, environmental and application limits, and parameter settings.
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Using Rotamass Total Insight for a SIS application
Safety PLC/DCS
Actuators
4-20 mA output1
4-20 mA output2
Mass flow rate
Density
Temperature
2 Using Rotamass Total Insight for a SIS application
For more detail information, refer to FMEDA report.
(YEC 20-02-160 R002 V1R2 FMEDA ROTAMASS TI)
The documents can be downloaded from the website of Yokogawa or purchased from the
Yokogawa representatives.
Website address: http://www.yokogawa.com/fld/
2.1 Safety function
The Rotamass Total Insight Coriolis flow meter for HART communication is intended for
use as a mass flow, fluid density and fluid temperature measurement component in a
Safety Instrumented System. It has one or two 4 – 20 mA analog outputs and other I/Os.
The flow meter must be used with one of the two or both 4 – 20 mA outputs to feed signals to a logic solver that is part of the safety instrumented function (SIF) as shown in the
following figure. The fault annunciation mechanism is an out of-range analog current. In
order to take advantage of the automatic diagnostics in the flow meter, this annunciation
mechanism must be connected.
Safety function
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Fig.1: Example Safety Instrumented Function
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Safety accuracy
Using Rotamass Total Insight for a SIS application
2.2 Safety accuracy
The Rotamass Total Insight Coriolis flow meter has a specified safety accuracy of 2 %.
This means that internal component failures are listed in the device failure rate if they will
cause an error of 2 % or greater.
2.3 Diagnostic response time
The Rotamass Total Insight Coriolis flow meter will report an internal failure within 3
minutes of fault occurrence for amplitude errors and within 7 seconds of fault occurrence
for all other errors (e. g. frequency error, signal fault).
2.4 Setup
During installation the flow meter must be set up with engineering unit parameters. This is
typically done with a field communicator. These parameters must be verified during the
installation to insure that the correct parameters are in the flow meter. Engineering range
parameters can be verified by reading these parameters from the optional local display or
by checking actual calibration of the flow meter.
Proof-Testing of the flow meter must be done after parameter setting.
2.5 Proof testing
The objective of proof testing is to detect failures within the flow meter that are not detected by the diagnostics of the flow meter. Of main concern are undetected failures that
prevent the safety instrumented function from performing its intended function. The frequency of the proof tests (or the proof test interval) is to be determined in the reliability
calculations for the safety instrumented functions for which the flow meter is applied. The
actual proof tests must be performed more frequently, or as frequently as specified in the
calculation in order to maintain the required safety integrity of the safety instrumented
function.
The following tests need to be specifically executed when a proof test is performed. The
results of the proof test need to be documented and this documentation should be part of
a plant safety management system. Failures that are detected should be reported to
Yokogawa.
Step Action
1. ▶ Bypass the safety function and take appropriate action to avoid a false trip.
2.
3.
4.
5.
6.
7. ▶ Cycle power to transmitter so RAM soft errors are cleared.
8. ▶ Remove the bypass and otherwise restore normal operation.
1)
This tests for possible quiescent current, low loop voltage and high loop impedance re-
lated failures.
▶ Verify plausibility of current with flow tube filled and zero flow rate within
stated accuracy.
▶ Verify plausibility of current with flow tube filled at two different flow rates
able to be independently estimated to approximately 10 % accuracy.
▶ Use digital communications to retrieve process fluid temperature measure-
ment and verify against independent measurement.
▶ Use digital communications to retrieve any diagnostics and take appropriate
action.
▶ Send a digital command to the transmitter to go to the high and low alarm
level output state current and verify that the analog current reaches these
values.
1)
For details, refer to FMEDA No. YEC 20-02-160 R002 V1R2.
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Using Rotamass Total Insight for a SIS application
In case of non-IS 4 – 20 mA output, the proof test will detect 93.3 % of possible DU failures.
In case of IS 4 – 20 mA output, the proof test will detect 93.3 % of possible DU failures.
The following tools need to be available to perform proof testing:
▪ Flow meter display or alternatively for digital communication: HART field communica-
tor, PRM or FieldMate.
▪ Measurement instrument to verify output current.
▪ Reference temperature measurement as close as possible to the flow meter under
test.
The person(s) performing the proof test of the Rotamass Total Insight Coriolis flow meter
should be trained in SIS operations including bypass procedures, flow meter maintenance and company management of change procedures.
2.6 Repair and replacement
If repair is to be performed with the process online the Rotamass Total Insight Coriolis
flow meter will need to be bypassed during the repair. The user should set up appropriate
bypass procedures for that. Contact the Yokogawa sales office if this instrument requires
repair. The person(s) performing the repair and / or replacement of the Rotamass Total
Insight Coriolis flow meter should have a sufficient skill level.
Repair and replacement
2.7 Startup time
The Rotamass Total Insight Coriolis flow meter will generate a valid signal within 20
seconds of power-on startup.
2.8 Firmware update
In case firmware updates are required, they will be performed at factory. The replacement
responsibilities are then in place. The user will not be required to perform any firmware
updates.
2.9 Reliability data
A detailed Failure Mode, Effects, and Diagnostics Analysis (FMEDA) report is available
from Yokogawa with all failure rates and failure modes. The Rotamass Total Insight
Coriolis flow meter is intended for use in a Low Demand Mode. Low Demand Mode
means the average interval between dangerous conditions occurs infrequently.
The Rotamass Total Insight Coriolis flow meter is certified up to SIL2 for use in a simplex
(1oo1) configuration, depending on the PFDavg calculation of the entire Safety Instrumented Function. The development process of the Rotamass Total Insight Coriolis flow
meter is certified up to SIL3, allowing redundant use, with hardware fault tolerance of 1,
of the flow meter up to this Safety Integrity Level, depending the PFDavg calculation of
the entire Safety Instrumented Function.
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When using the Rotamass Total Insight Coriolis flow meter in a redundant configuration,
the use of a common cause factor (β-factor) of 2 % is suggested.
For details, refer to FMEDA No. YEC 20-02-160 R002 V1R2.
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Lifetime limits
Using Rotamass Total Insight for a SIS application
2.10 Lifetime limits
The expected lifetime of the Rotamass Total Insight Coriolis flow meter is 10 years. The
reliability data listed in chapter Reliability data [}6] is only valid for this period. The failure
rates of the Rotamass Total Insight Coriolis flow meter may increase sometime after this
period. Reliability calculations based on the data listed in chapter Reliability data [}6] for
Rotamass Total Insight Coriolis flow meter lifetimes beyond 10 years may yield results
that are too optimistic, i.e. the calculated Safety Integrity Level will not be achieved.
For details, refer to FMEDA No. YEC 20-02-160 R002 V1R2.
2.11 Required parameter settings
The following parameters need to be set in order to maintain the designed safety integrity.
4 – 20 mA output setting One of the following values should be set:
▪ Mass flow
▪ Density
▪ Temperature
Write lock setting The parameter “write lock” should be set to “All locked”.
High-Low (Burnout) switch To specify if the output should go high (> 21.6 mA) or low
(< 2.4 mA) upon detection of an internal failure.
Write Protect (Security) The write function should be disabled.
The detail is described in the user’s manual and the software instruction manual of
Rotamass Total Insight.
2.12 Environmental limits
The environmental limits of the Rotamass Total Insight Coriolis flow meter are specified in
the applicable General Specifications (GS) of Rotamass Total Insight.
2.13 Application limits
The application limits of the Rotamass Total Insight Coriolis flow meter are specified in
the applicable General Specifications (GS) of Rotamass Total Insight.
If the flow meter is used outside of the application limits the reliability data listed in chapter Reliability data [}6] becomes invalid.
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Definitions and abbreviations
3 Definitions and abbreviations
3.1 Definitions
Safety
Freedom from unacceptable risk of harm.
Functional safety
The ability of a system to carry out the actions necessary to maintain a defined safe state
for the equipment / machinery / plant / apparatus under control of the system.
Basic safety
The equipment must be designed and manufactured such that it protects against risk of
damage to persons by electrical shock and other hazards and against resulting fire and
explosion. The protection must be effective under all conditions of the nominal operation
and under single fault condition.
Verification
The demonstration for each phase of the life-cycle that the (output) deliverables of the
phase meet the objectives and requirements specified by the inputs to the phase. The
verification is usually executed by analysis and / or testing.
Definitions
Validation
The demonstration that the safety-related system(s) or the combination of safety related
system(s) and external risk reduction facilities meet, in all respects, the Safety Requirements Specification. The validation is usually executed by testing.
Safety assessment
The investigation to arrive at a judgment – based on evidence – of the safety achieved by
safety-related systems.
Safety Freedom from unacceptable risk of harm.
The ability of a system to carry out the actions necessary to
Functional safety
maintain a defined safe state for the equipment / machinery /
plant / apparatus under control of the system.
The equipment must be designed and manufactured such
that it protects against risk of damage to persons by electrical
Basic safety
shock and other hazards and against resulting fire and explosion. The protection must be effective under all conditions of
the nominal operation and under single fault condition.
The demonstration for each phase of the life-cycle that the
Verification
(output) deliverables of the phase meet the objectives and requirements specified by the inputs to the phase. The verification is usually executed by analysis and / or testing.
The demonstration that the safety-related system(s) or the
combination of safety related system(s) and external risk re-
Validation
duction facilities meet, in all respects, the Safety Requirements Specification. The validation is usually executed by
testing.
Safety assessment
The investigation to arrive at a judgment – based on evidence
– of the safety achieved by safety-related systems.
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Further definitions of terms used for safety techniques and measures and the description
of safety-related systems are given in IEC 61508-4.
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Abbreviations
Definitions and abbreviations
3.2 Abbreviations
Value Name / Description
DU Dangerous Undetected
FMEDA Failure Mode, Effects and Diagnostic Analysis
IS Intrinsically safe explosion-proof
non-IS Non-intrinsically safe explosion-proof
PFDavg Average Probabilty of Failure on Demand
PLC/DCS Programmable Logic Controller / Distributed Control System
PRM Plant Resource Manager
SIF Safety Instrumented Function
SIL Safety Integrity Level
SIS Safety Instrumented System
SLC Safety Lifecycle
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TRADEMARKS
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ISO 9001
HART: registered trademark of FieldComm Group, Inc., US
ROTAMASS: registered trademark of Rota Yokogawa GmbH & Co. KG, DE
FieldMate: registered trademark of YOKOGAWA ELECTRIC CORPORATION
All other company and product names mentioned in this document are trade names, trademarks or
registered trademarks of their respective companies. In this document, trademarks or registered trademarks are not marked with ™ or ®.
All rights reserved. Copyright © 2020-05-13
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