Intrinsically Safe Gas Transmitter Ensuring Safety & Reliability for Oil & Gas Plants
Overview
The client needed a compact, low-power gas transmitter that complied with hazardous area standards (IS/ATEX) and was ready for SIL2/3 certification under IEC 61508. The solution had to integrate seamlessly with existing plant systems via HART communication while ensuring high reliability, safety, and ease of maintenance.
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Challenges
Lack of an intrinsically safe, low-power hardware platform with SIL2/3 readiness for hazardous environments
Absence of seamless HART integration and certification-ready design, delaying compliance and plant system adoption
Solution
- Developed a compact, low-power, intrinsically safe (IS) hardware platform with full HART communication stack for hazardous environments
- Designed a plug-and-play sensor module for quick replacement & maintenance
- Integrated safety-critical applications with self-test libraries, diagnostic alarms, and predictive maintenance capabilities
- Performed EMI/EMC pre-compliance testing and prepared certification-ready design documentation for IS/ATEX
- Performed functional safety analysis as per IEC 61508 to ensure SIL2/3 readiness
- Designed and deployed an automated end-of-line test system for power-up/ICT, peripheral validation, auto-calibration, and primary functional checks
- Built modular test fixtures with pogo-pin interfaces and automated reporting for traceability and faster validation cycles
Outcomes
- Delivered a reliable, low-power transmitter with seamless HART integration, ensuring extended device life and smooth plant adoption
- Achieved SIL2/3 readiness and first-cycle compliance, accelerating certification and product launch in hazardous environments
