Standards Certification Education & Training Publishing Conferences & Exhibits Implementing Safety Instrumented Burner Management Systems: Challenges and Opportunities Mike Scott, PE, CFSE
Standards
Certification
Education & Training
Publishing
Conferences & Exhibits
Implementing Safety
Instrumented
Burner Management Systems:
Challenges and Opportunities
Mike Scott, PE, CFSE
Presenter
Mike Scott, PE, CFSE Executive Vice President Global Process Safety
• B.S. Mechanical Engineering - University of Maryland • Masters of Engineering - University of South Carolina • Licensed Professional Engineer - AK, GA, SC, and IL • Certified Functional Safety Expert (CFSE) • Voting member of ISA S84 committee on
Electrical/Electronic/Programmable Electronic Systems (E/E/PES) for Use in Process Safety Applications
• Chairman of the ISA S84 Working Group on Performance Based Fire & Gas Systems
• ISA S84 BMS sub-committee member and liaison to the America Boiler Manufacturer’s Association (ABMA) and NFPA 86
• IEC 61511 committee member • ISA Safety and Security Division Director - Elect • ISA 2015 PCS Symposium Safety Chair • ISA Training Course Developer / Instructor • ISA Fellow
2
Challenges & Opportunities
• Possibly new field devices
• New Safety PLC
• If BMS upgrades treated as stand
alone projects, it will be costly and
take many years to remove risk from
the business
• Typically risk analysis will result in
missing SIFs, improperly defined SIFs
and orders of magnitude differences
in SIL targets for like SIFs / unit
operations
Applying the safety lifecycle to
existing brownfield BMS
installations typically results in
capital projects to close gaps
Capital Project Chaos!
Safety Lifecycle Tasks
Process Hazard Analysis
Layer of Protection Analysis
Safety Integrity Level (SIL) Selection
Safety Requirements Specification
SIL Calculations & Verification
Functional Test Plans
Functional Safety Assessments¹
¹ Stages 1, 2, & 3
What if I could
COPY and PASTE???
5
Instrumentation &
Control System Design Tasks
• Instrument Approved Vendors List in line
with SIL Calculation assumptions
• Instrument Datasheets
• Instrument Index
• I/O List
• Control Panel Design w/ Bill of Materials
• Control Panel Internal Wiring
• Field Wiring (Loops / Swing Arms /
Schematics)
• Control System Architecture Diagram
• Instrumentation and / or Electrical
Installation Details
• Instrument Approved Vendors List in line
with SIL Calculation assumptions
• Instrument Datasheets
• Instrument Index
• I/O List
• Control Panel Design w/ Bill of Materials
• Control Panel Internal Wiring
• Field Wiring (Loops / Swing Arms /
Schematics)
• Control System Architecture Diagram
• Instrumentation and / or Electrical
Installation Details
• Cable / Conduit Block Diagram
• Cable Schedule
• Software Requirements Specification
• Logic Solver Configuration
• Logic Solver Simulation Logic
• Local Flat Panel Configuration
• Historian Configuration
• Remote BPCS HMI Configuration
• Factory Acceptance Test Procedure /
Testing
• Site Acceptance Test Procedure / Testing
• Commissioning Test Procedures / Testing
What if I could
COPY and PASTE???
6
Operations & Maintenance Tasks
• Functional Test Plans, Instrument Calibration, Valve Leak Testing
loaded and scheduled into the site Computerized Maintenance
Management System (CMMS) per Proof Test Coverage
assumptions in SIL Calculations
• Spare Parts in Stores per Mean Time To Repair assumptions in SIL
Calculations
• Operations / Maintenance Trained on new SI-BMS
• Program / personnel in place to track Time in Bypass, Demand
Frequency, Cause Frequency, Dangerous Undetected Failures, and
Late / Incomplete Testing of SIFs per IEC 61511 requirements
What if I could
COPY and PASTE???
7
Configuration File
Safety / Software Requirements
Auto
Configure
Safety PLC
SI-BMS Templatization Methodology
Intelligent Engineering
Drawings Store Templates
Safety Lifecycle
Management Toolkit Store Templates
Auto
Test
Test Engine
Results
Auto
MoC
8
SI-BMS Templatization Execution
• Templates – Leverage
established design standards to
ensure high quality, consistent
deliverables
• Testing – Develop design
methodology that maximizes
automated testing for critical
information capture
• Team – Dedicated high
performing small teams to execute
SI-BMS Upgrades
9
SI-BMS Templatization Savings
• Cost – Using SI-BMS approach
leveraging small, high performing
teams to implement standard
templates and testing schemes
• Schedule – Operations
approval of entire SI-BMS
functionality prior to FAT to ensure
outage/TAR schedule is safely
achieved
• Quality – Continuous
improvement gains quickly realized
by using dedicated teams executing
standard designs with automated
testing
Projects moving forward
$
10
COST SAVINGS!!!
x → 60%
Traditional project execution
What if I could COPY and PASTE???
Safety Lifecycle
I&C System Design
O&M Activities
TOTAL
x → 75%
x → 70%
x → 35%
x → 60%
11
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