Post on 19-Jan-2015
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Scalable Process Safety
Kevin CollotonTechnology Manager - Safety
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Agenda Sample
1. Process Safety Market
2. Safety Applications
3. Safety System Options
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Process Safety Applications & Market
• Historically there are these major types of Process Safety Applications:– Emergency Shut Down (ESD) 41%– Fire & Gas (F&G) 24%– Critical Control (CC) 7%– Burner Management (BMS) 10%– Turbo Machinery 14%– Other
• Within these major industries– Oil & Gas– Refining– Chemical– Pharmaceutical– Power Generation
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Process Applications & Safety
• Historically Process applications use two Automation Systems to control the site / application.– BPCS Basic Process Control System (DCS)– SIS Safety Instrumented System
• In Process Control it is common that the SIS NEVER performs!– If the BPCS operates without faults or problems, the SIS may
never intervene / take action.BUT– If the BPCS fails and is unable to perform, the SIS MUST
work correctly! Not to control, but to shutdown in a controlled manner.Because if it doesn’t, will other measures be sufficient?• LOPA – Layers of Protection Analysis
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SIS Safety Instrumented System
• Because of this importance many years ago industry best practice determined that SIS features implement / satisfy key requirements:– Separation and Diversity being important
• Physical separation from the BPCS– To reduce the risk of an external single event affecting both
systems• Diversity from the BPCS
– To reduce the risk of an internal event affecting both systems (common cause due to design commonality)
• High Availability– To reduce / eliminate nuisance trips– An unexpected / untimely shutdown could be hazardous
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Safety Applications
High Demand Low DemandMachine Safety
• Safety Demand <1 hrISO 13849IEC 62061
Process Safety• Safety Demand 1 yr >
IEC 61511
Sector StandardsEN 298, 746, 50156
NFPA 85, 86More ….
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Low Demand Safety Dynamics
• Of the Traditional Process Safety Applications:– Emergency Shut Down (ESD)– Fire & Gas (F&G)– Critical Control (CC)– Burner Management (BMS)– Turbo MachineryThese three process safety applications virtually always use a well recognized & reputable SIS Vendor.– Diversity is critical– Scalable safety – Scalable size– High Availability is typically required
Low Demand
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Safety System Enhancements
• Over the last decade significant new safety technologies– SIL 3 rated communications (Black Channel)– Common communication protocols– Varying levels of software compatibility between the BPCS and SIS– Varying levels of hardware compatibility between the BPCS and SIS
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Example of modern Scalable SIS
• AADvance SIS– Scalable in size– Scalable in safety– Scalable in Availability
• Same components• CIP Communications
– Easy to communicate with the BPCS• Programmed with ISAGraph
Workbench
• Used in conjunction with a BPCS
1oo1 SIL2 CPUSimplex I/O
1oo2 SIL3 CPUSIL3 Duplex I/O
High Availability CPUHigh Availability I/O
2oo3 SIL3 TMR CPU SIL3 TMR I/O
Voting High Availability
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Process Machinery?
• Of the Traditional Process Safety Applications:– Emergency Shut Down (ESD)– Fire & Gas (F&G)– Critical Control (CC)– Burner Management (BMS)– Turbo MachineryThese two applications often have different requirements– They typically don’t implement a BPCS and SIS– They often have safety demands at a higher rate than low demand
• Not machine safety (high demand), but more than process (low demand)– They often don’t require high availability solutions
– In Europe these applications need to consider the EU Machinery Directive. • The MD does not recognize IEC 61511 (process safety standard)• The MD only recognizes IEC 62061 or ISO 13849 – Machine Safety
Safety Applications New Considerations
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High Demand Low DemandMachine Safety
• Safety Demand >1 hrISO 13849IEC 62061
Process Safety• Safety Demand <1yr
IEC 61511
Sector StandardsEN 298, 746, 50156
NFPA 85, 86More ….
Machinery Directive (2006/42/EC)
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Process Machines?
• Many have flame or heat control• All are portable (not built on site)• All have machine control elements, and also process control elements• A range of standard automation requirements, (size, speed, sophistication)• A range of safety requirements (simple safe off, zoning, simplex, high availability,
speed, SIL2, SIL3)
Furnace Thermoforming Turbo Machinery
Safety, just like Standard isn’t one size fits all.
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Safety Applications
High Demand Low Demand
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User / Customer Preferences
• Just as in standard automation, safety customers have choices in size, performance, availability, commonality (integration).
• Today users have world class solutions to choose from:• Diversity with communications integration• Fully integrated (software and hardware)
AADvance
Customers can leverage modern system flexibility to reduce plant complexity and improve compliance to virtually any safety
requirement
GuardLogix
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