Restricting ignition in your process operation

Maintaining Safety,
Maximising Efficiency
and Minimising Costs
Table of Contents

3 Introduction
4 How safe is your asset?
5 A safe solution
6 Restricting ignition

7/8 Main challenges for the maintenance/instrument engineer

9 Safety
10 Asset sustainability
11 Operational complacency
12 Human reliability
13/14 Application
13 Controlling O2 through direct monitoring
14 It is time to change your LOC process

15/16 TDLS – the smart way to ensure safety

17 Safety under control

18/19 Safety at every stage

20/21 Features and benefits of Yokogawa’s TDLS technology
Introduction
How safe is your asset?
How safe is your asset?
Fire and explosion are the biggest inherent hazards
facing the chemicals industry.
The uncontrolled ignition of flammable components such as methane (CH4), carbon
monoxide (CO), and hydrogen (H2) in the presence of combustion supporting oxygen
(O2) can make chemical processing a hazardous activity, particularly in combustion.
Not only is there a potential safety risk with burning combustible materials, but the
by-products are often combustible too.

It is essential for operators to be able to minimise the hazards of ignition, combustion

and explosion. This includes ensuring there are no leakages in the heat exchanger or
pipelines, which can further fuel the combustion process. Current emission regulations
must also be complied with.

Modern chemical processing is based around three main objectives: maximising

production, minimising cost, and ensuring safety is not compromised. But how can
you achieve all three at the same time?

Unfortunately, the limitations of conventional technologies severely impact the

capabilities of operators, maintenance and instrument engineers to meet this triple
challenge effectively.

INTRODUCTION 4
A safe solution
Ensuring your asset and instruments are maintained so that your
colleagues can work in a safe environment is your highest priority; and
safety supports the other two objectives of increased efficiency
and minimised costs.

Rather than saving money, hazardous operations non-contact, and direct O2 measurement with less
and working processes will actually cost much more minimum downtime and assured improvements in safety
due to production inconsistencies and downtime. At and negligible delay time to detect; and it is easy to apply.
worst, lack of safety can lead to a hazardous incident
This is a major development in supporting maintenance
or explosion with potentially catastrophic
and instrument engineers as they reduce the threat of
consequences. Because of their limitations,
hazards while ensuring maximum operational efficiency
conventional analyser technologies have prevented
and lower costs.
operators from running their processes in the safest
manner – without them ever being aware.

Yokogawa’s Tunable Diode Laser Spectrometer

It is a step change in the industry’s
(TDLS) analyser system provides a safe solution to this
challenge. It is a step change in the industry’s ability
ability to operate safely by allowing
to operate safely by allowing O2 control while O2 control while answering the need
answering the need for maximum efficiency and for maximum efficiency and
minimised costs. minimised costs.
The TDLS is designed according to IEC 61508 and
certified SIL2 by exida. It provides reliable, real-time,

INTRODUCTION 5
Restricting ignition
Ignition needs three basic elements to occur – a combustion supporting
gas (O2), heat and flammables. In order to maintain safe operations,
it is imperative to control the elements that allow ignition to take place.

HEAT

Flam-
O2
mables

INTRODUCTION 6
Main challenges for the
maintenance/instrument engineer
Safety
Asset sustainability
Operational complacency
Human reliability
Main challenges for the
maintenance/instrument engineer

X
Safety Asset sustainability Operational complacency Human reliability

MAIN CHALLENGES FOR THE MAINTENANCE/INSTRUMENT ENGINEER 8

Main challenges for the
maintenance/instrument engineer
Safety
When a hazardous incident occurs, every second counts.

Conventional gas detection analysers are constrained by

time-delaying processes, including the identification and
analysis of chemical elements. These processes can hold up
response – whether for maintenance or, in the worst case, a
shut down.

By delivering trustworthy, real-time in situ and holistic data

for the timely identification and control of O2 and other gases,
the TDLS technology ensures maximum safety and operational
efficiency. It is also capable of being fully maintained in the
field which minimises downtime.

MAIN CHALLENGES FOR THE MAINTENANCE/INSTRUMENT ENGINEER 9

Main challenges for the
maintenance/instrument engineer
Asset sustainability
Your focus is on continuous improvement. It is not just about reducing
hazards for your plant and your colleagues; it is about improving your
workplace processes too.

That means making sure your asset is run in a sustainable way.

Unfortunately, many chemical plants currently use outdated
and wasteful diagnostics processes and controls that cannot
provide the required data. But TDLS technology can help you
avoid these problems by delivering real-time, trustworthy data
with line of sight, open path and free space measurement.

MAIN CHALLENGES FOR THE MAINTENANCE/INSTRUMENT ENGINEER 10

Main challenges for the
maintenance/instrument engineer
Operational complacency
Your asset has run without a hazardous incident for several years and
your operations manager is happy with the monthly reports, so why
would you spend money on improving safety?

This type of thinking is based on the notion that if
everything is working fine right now, and everybody
is familiar with the same old daily operations, there
is no need to improve anything. This creates a false
sense of security regarding asset safety and leaves
you vulnerable to human error.
For example, furnace firing rate controls have
changed little over 40 years and manual firing
is still common practice. The ignition hazard
from conventional analysers requires them to be
switched off before firing. This means you cannot
measure your gas composition in this crucial stage.
However, because TDLS analysers do not come into
contact with the gases, they do not carry that risk.
In fact, TDLS analysers can be run throughout the
whole process and identify hazardous conditions
before, during and after firing.
Air-to fuel ratio control is only used on a few
systems, and even fewer conventional systems
compensate for changing fuel composition. This
can create a hazard. Feedback measurements
are minimal and, are limited by the capability
constraints of conventional analysers.
In all likelihood you are running an aging system,
so modern emissions may well exceed its design.
But how do you know?

MAIN CHALLENGES FOR THE MAINTENANCE/INSTRUMENT ENGINEER 11

 Main challenges for the
maintenance/instrument engineer
Human reliability
An aging workforce has seen the industry lose many of its most
skillful operators. Yet, no matter how experienced workers are, we all
make mistakes. In a chemical facility, those mistakes can
lead to hazardous incidents or even explosions.

X
Unfortunately, reliance on limited data outputs from
conventional analyser technology places a greater onus
on the skills of the operator to avoid incidents. These
skills can vary for several reasons including experience,
knowledge of the system and the quality of the training/
induction received by the operator. Also, traditional
analysers require human calibration – another potential
hazard source.

TDLS technology reduces human error by delivering

the most trustworthy data as quickly as possible. Its
high degree of accuracy enables automation of the
control system based on the response of the analyser –
something that less reliable conventional technologies
cannot offer.

MAIN CHALLENGES FOR THE MAINTENANCE/INSTRUMENT ENGINEER 12

Application
Controlling O2 through direct monitoring

Ignition requires a combination of heat, flammables and O2. In order

to limit risk and ensure the safety of your asset and your workmates, it
is imperative that you have the ability to detect, measure, control and,
above all, limit O2 concentration (LOC).

An oxygen concentration of 8% or above increases the risk of

explosion. For example, a platformer creates H2 as a by-product.
To prevent ignition of this H2, the O2 concentration should be
continuously controlled at less than 2 percent.

MAIN CHALLENGES FOR THE MAINTENANCE/INSTRUMENT ENGINEER 13

Application
It is time to change your LOC process

The timely monitoring and analysis of gases including O2 is critical in

reducing the potential for hazardous incidents and achieving optimal
performance from your asset.

However, conventional technologies rely on highly

complex and costly sampling procedures that slow down There are five reasons why sampling may
the time it takes for you to receive this important data. be delayed:
TDLS technology has no contact with the gas and has no • Sample tapping at an inappropriate
moving parts, making it extremely reliable and accurate in location in the process pipes
identifying hazards and maximising efficiency. It also
• Using too large a probe during
eliminates the frequent and extensive maintenance and
extraction of the sample
costly downtime linked to conventional sample
conditioning systems. Instead, it provides real time, • Using a long pipe during sample transfer
trustworthy data so you can act fast. can generate an unstable flow
• Adjustments to the sample through
filtering or coalescence
• The lengthy response times of
conventional analysers

MAIN CHALLENGES FOR THE MAINTENANCE/INSTRUMENT ENGINEER 14

TDLS – the smart way to ensure safety
TDLS – the smart way to ensure safety
The TDLS analyser consists of a laser that produces infrared light, optical
lenses to focus the laser light through the gas to be measured and then on to
a detector. Electronics control the laser and translate the detector signal into
data to determine the gas concentration.

Gas molecules absorb light at specific wavelengths, called

absorption lines. TDLS works by measuring the amount
of laser light that is absorbed (or lost) as it travels through
the gas being measured. The degree of loss equals the
concentration of the gas.

Unlike conventional analysers, which use wavelength

modulation spectroscopy, TDLS uses a gas molecule
measurement based on absorption spectroscopy. This
makes it less sensitive to changes in conditions and
means it can deliver more trustworthy data.

No sensor contact with the gases and no moving parts

mean consistently high performance in delivering the
fastest, most reliable information on your asset’s safety.

TDLS – THE SMART WAY TO ASSURE SAFETY 16

Safety under control
TDLS offers specific safety benefits
when it comes to monitoring your pipelines.

Because the flow of gas usually fluctuates, analysing

gas concentration can be difficult. However, the TDLS
analyser allows you to maintain a steady and stable gas
flow in your pipe by creating an ‘air curtain’.

Conventional analysers can be damaged by the gasses

and processes that they measure and require costly
maintenance leading to increased downtime. The TDLS
analyser avoids this problem. It has no contact with
the gas and is contained in a strong, corrosion-free,
flameproof casing with the added option of a sapphire
window for corrosive environments.

TDLS – THE SMART WAY TO ASSURE SAFETY 17

Safety at every stage
Safety at every stage
The high reliability of Yokogawa’s TDLS technology enables long-term
operational consistency and real time measurement to ensure safety
and stability in your processes.

The TDLS changes the immeasurable to the measurable, changes in time to real time and change
monitoring to optimisation.

CO, CH4, O2 and H2S can be detected prior to ignition across a wide
temperature range.

Path average measurement provides a complete understanding of

gas concentration levels.

30m
An optical path of up to 30m for optimal visibility.

Operates in corrosive environments.

Rapid data delivery helps you respond quickly.

SAFETY AT EVERY STAGE 19

Features and benefits of Yokogawa’s TDLS technology
Features
✔ Fully field repairable and
50-day record storage
✔ Reference cell
✔ SIL2 certified
Benefits
TDLS technology can be maintained in situ without being removed
from the installation point. Its modular structure provides ultimate
flexibility on site, and all parts are fully interchangeable. Also, as
there is no need to recalibrate the system after a changeover, it
does not need to be removed from the process pipe.
This helps to ensure accurate measurement even in cases
where this is a ‘zero value’ or ‘no absorption’ monitoring.
To meet your safety requirements, The TDLS is designed according
to IEC 61508 and certified SIL2 by exida. When used in a single set
configuration, and SIL3 certified when used in a dual set configuration.
SAFETY AT EVERY STAGE 20
Features and benefits of Yokogawa’s TDLS technology

Features Benefits

✔ Plug and Play Avoiding a stop in your processes for repairs means you
can maintain operational stability, which also enhances the
safety of your asset. Parameters for the smart laser optics
are all preset in the factory, so the TDLS analyser comes
ready to use out of the box.

Drawing on many years of experience, Yokogawa’s TDLS

✔ Safety
technology represents a step change in enabling
managers to reduce the threat of hazardous incidents
while enabling maximised output and minimised costs
in chemical facilities around the world.

TDLS8000 TDLS8100

SAFETY AT EVERY STAGE 21

Thank you for taking the time to read this ebook.
Want to see TDLS in action?
Do you have any further questions?
Contact us here:
Yokogawa Electric Corporation
World Headquarters
9-32, Nakacho 2-chome, Musashino-shi, Tokyo 180-8750, Japan
ana-eSales@ml.jp.yokogawa.com IAMKP-1785-19-006
www.yokogawa.com/an/

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