Roxel Solutions Presentasjon Teknologidag 2014

Teknologidag – 5 Juni 2014

New regulations for offshore rigs

Jan Forsell – Roxel Solutions AS

My background:

Siemens O&G:- Responsible for F-systems, offshore- Eng manager, Eldfisk SAS upgrade- Eng manager, Statfjord Safety Systems

F&G, ESD, HIPPS, IOPS, OPPS- Project manager, Safety systems

Roxel Solutions AS:- General manager

Jan Forsell – Roxel Solutions AS

Agenda:

• A minute about Roxel

• Short introduction to norms, standards and NPD rules

• SIL in Control System Projects – How to approach?– Rules and regulations– Project execution and verification– Programming tools– Equipment

Roxel Group

• Revenue: 240 MNOK • Resources: 140• 13.400 m2

Supplier of onshore and offshore solutions

LANDBASERT

Drilling equipment packages

Independent system integration of 3’rd party suppliers

Product line:

• Drilling and utility systems• Cabins and LER• Instrumentation• EX equipment• Drives

Mud & Cement – Integrated Solutions

MUD HANDLING SYSTEM

COMPLETE MUD & CEMENT SYSTEM

References PSD EXPRO – Well Testing:

– 6 PSD SIL2 systems delivered– NORSOK – IEC61508/511/OLF070 – DNV– EX zone 1

Halliburton – Well Testing:– 1 PSD system, Under Balanced Drilling– 2 PSD systems, Well Testing

New PSD system presentation Challenges:

High risk potentialHarsh environment Critical processPortable equipment

SAFETY SYSTEMS - Offshore

Safety Systems - OffshoreSafetyIntegrityLevel

SIL4: Not used offshore (Nuclear power plants, train signalling systems)SIL3: Emergency/Critical systems (ESD/HIPPS)SIL2: Process and protection systems (PSD/F&G)SIL1: Lowest level, not used offshore

Safety Instrumented Systems (SIS)

SafetyIntegrityLevel

SIL4: Not used offshore (Nuclear power plants, train signalling systems)SIL3: Emergency/Critical systems (ESD/HIPPS)SIL2: Process and protection systems (PSD/F&G)SIL1: Lowest level, not used offshore

Safety Integrity Levels:

Focus on the complete system (Equipment Under Control)Mandatory risk evaluations – must be documented (SRS)Supplier must document that SIL is obtained

Focus on the complete lifecycle:

Design-Specification-Engineering-Testing-Operation-Demolition

Standards for implementation offshore:

Ptil, Styringsforskrift §5 barriersPtil, Innretningsforskriften §8 safety functions

IEC61508 – Functional safety of control systems, framework, definition of SILIEC61511 – Engineering of safety systems for Process systemsOLF070 – NPD Guideline for minimum SIL levels on the NCS: - Define SIL levels, guidance on how to implement NPD demands

API RP 14C – Risk analysis, failure-mode-effects analysis (FMEA) and hazard-and-operability studies (HAZOPS), define risk levels and barriers, safe charts.

OLF070 specifies API RP 14C / ISO10418 (guideline for analysis, design, installation and testing of process safety systems)

Connections between IEC norms:

Standards for implementation for rigs:

DNV-OS-A101 – Safety Principles and Arrangements

Basic requirments for DNV verification, shutdown logic and alarms.

Standards for implementation rigs:

DNV-OS-D202 – General requirements for safety and control systems: Design, fabrication, installation, testing, commissioning, operation, mainenance, re-qualification, and abandonment.

Availability class (R0) redundancy

Documentation,Ch3.1 Table B2

NORSOKThe D series: Ongoing updates after Macondo incident:

D-002: Well Intervention, BOP SIL demand (also for well intervention)D-007: Well testing, mandatory SIL2 demand after july 2017

NORSOK points to OLF070 for minimum level.

What must be adressed in a SIL project?

BeforeStartDuringAfter

- Government requirements- Customer demands- Internal requirement- Certifying body (DNV/ABS/…)

How to implement:- How to interpret Rules & Regulations- Failure Mode Effect Analysis (FMEA)- Hazard and operability studies (HAZOP)

- Documentation for SIL:Functional Design Specification (FS/FDS)Safety Requirement Specification (SRS)Safe Charts with Cause & EffectSIL loop definition

What must be adressed in a SIL project?

BeforeStartDuringAfter

Interface Meeting:- How to interpret Rules & Regulations- How to document that SIL level is achieved- Responsibility interfaces

Technical (Instrumentation and loops)Formal meetingsContact with certifying body

What must be adressed in a SIL project?

BeforeStartDuringAfter

Personnel qualification:

- Key personnel must be qualified and trained:- Project management- Lead engineers

What must be adressed in a SIL project?

BeforeStartDuringAfter

Ensure that SIL is achieved:

- Project quality control- Documented traceability- Testing and verification- Documented conformity

What must be adressed in a SIL project?

BeforeStartDuringAfter

Project quality control according to ISO9001:

• QA Plan with QA Activity List:- Technical Reviews (FDS/SW/HW/HMI)- Validation according to IAT/FAT procedures

• Safety Assessment and Validation Plan (SA&VP)- Identify and manage all safety aspects - How to verify and test (Nordtest Checklists)- How to implement IEC61508/511/OLF070- Change management (Risk&Impact analysis)

• Node Book:- All required design documents and reports

What must be adressed in a SIL project?

BeforeStartDuringAfter

Installation and Commissioning:

• Procedures for - Storage and transportation- Installation - Commissioning - Testing

• Training:- Operator and Maintenance personnel

What must be adressed in a SIL project?

BeforeStartDuringAfter

After delivery:

• SIL level must be maintained throughout the system lifetime:

- Documentation- Test intervals (instruments and control system)- Modifications and reconfiguration- Repair

Roxel is approved as Solution Integrator by Siemens:

International program:1300 partners world wide7 partners in Norway

Roxel is approved for the following areas:

Process Control System SIMATIC PCS7, specializing on PCS 7 Safety Human Machine Interface SIMATIC HMI Automation System SIMATIC

How the program works:

Support network- Siemens IADT in Oslo- Product experts in Germany

Competence through mandatory training- SIL courses in Germany (3 x 2 weeks)- Work shops- Partner Summits- Information on new products- Demo busses

Siemens Safety Integrated

Why Siemens:

• Most common standard for O&G

• Largest portefolio of IEC61508 equipment

• Reliable and well proven

• Simatic expertise within Roxel

Siemens Safety Integrated Safety according to IEC 61508/61511:

– Programming based on Siemens F-Tools:- Part of Simatic PCS 7 tools- Tested by TÜV

– Equipment based on SIMATIC Safety Integrated Systems (SIS):- S7-315F, single Fail-safe SIL2/3- ET200iSP combine SIL and Ex- F-SM I/O modules «Yellow series»

– Equipment based on SIMATIC PCS7:- S7-400F, single Fail-safe SIL2/3- Safety Matrix- ET200iSP combine SIL and Ex- F-SM I/O modules «Yellow series» Communication:- ProfiSAFE Single communication for Zone 1

Design review by 3rd party (Sintef, DnV, Scanpower…)

Small systems

S7-300F:

• CPU: S7-315F mid-range SIL 3 w/ProfiSAFE DP• Integrated F-SM i/o-cards AI/DI/DO• Redundant power

Benefits:

+ Cheap hardware+ F-SM in one box AI/DI/DO+ Based on F-Library IEC1311 by TÜV+ Good for Small systems with low degree of changes

PCS 7 systems

Technology:– Siemens S7-400 PLC

Software:– Siemens PCS 7– Safety Matrix

Benefits:+ Simplified programming+ More configuring+ Simplified documentation+ Close integration between logic and HMI+ Single or redundant+ Powerful

Drawbacks:÷ More expensive than S7-300, but cheaper in the long run…÷ Larger in size

RIO units – Safe area Protection level IP20 Operating range 0...60°C (-20...60°C) Redundant connection (for H CPUs) I/O Module Redundancy (1 Sensor -> 2 Modules) Modularly expandable Max. 12 I/O modules per station I/O Modules with comprehensive diagnostics

Power supply Interface module for Profibus DPIM153-2

I/O moduleExpandablebackplane

Aluminium rail

RIO units – Ex zone 2 or 1 - ET200iSP ET200iSP

– Specifications:- AC 85 … 264VAC- -20C … +70C - ATEX II 2 G (1)

Ex de [ia/ib] IIC T4

– Profibus DP:- Intrinsic safe communication Ex ib- Plug/unplug under Ex conditions- Single (or redundant) communication- Active EOL compensation

– Power supply- Ex d- Redundant power

RIO units ET200iSP

– Possible housing:- EEx e for Zone 1 and 2- Wall mount- Stainless steel: DIN 1.4404 1.5 mm- Non-Corrosive materials- Expandable up to 32 modules

RS485-iS cables withBuccaneer

Cause & Effect Requirements:

– Flexibility– Online verification– SIL demands

Safety Matrix

Benefits

The SIMATIC Safety Matrix as - Engineering Tool- Real time Viewer

Configuration of the Safety Functions with the Cause & Effects Method

Automatic TÜV-certified Creation of the Safety Logic from the Cause & Effect matrix

Easy Configuration without special Programming Knowledge

Configuration, auto-generation and diagnostic tool for SIL3 application:

First-in alarm display and saving Integrated commands: bypass, reset, override, parameter modification Sequence of event display and savings Operator interventions Automatic version tracking Automatic documentation of modifications

Benefits

HMI

HMI

HMIHMI Screens

Alarm Screen – YA711

Process Screens

Trending

HART Interface

Simatic Process Device Manager HART Instrument Validation

Agenda:• One minute about Roxel• Short introduction to Safety Integrity Levels - SIL• SIL in Programmable Electronic Systems (PES):

– Rules and regulations– Project execution and verification– Programming tools– Equipment

PCS 7 systems

Technology:– Siemens S7-400 PLC

Software:– Siemens PCS 7– Safety Matrix

Benefits:– Less programming– More configuring– Simplified documentation

Drawbacks:– More expensive– Cheaper in the long run

Documentation DNV-OS-D202 October 2008 - AUTOMATION, SAFETY, AND TELECOMMUNICATION SYSTEMS

– System Availability: R0 - Continuous available

– Certification and Classification requirements:

Documentation

DocumentationNODE Documentation according to Safety Validation and Assessment plan

Section 1, General:

Functional Specification, FS, FDS, (SRS and SAR)Node Plan and Progress Reports Revision recordCPI, Computer Point IndexC&E's, SCD's, SEQUENCE LOGIC/SFC'sSerial Links SpecificationsStatic Pictures Design BasisChange LogOther technical basis documents (MOM, TQ etc)Node software backup

Section 2, Hardware:

System Block DiagramGeneral Arrangement DrawingsPower Distribution DrawingsHardware Typicals Equipment Lists / SPIRInterface and Connection DrawingsX-Wiring and Circuit Diagrams

Secton 3, Test Dossier:

Test procedure (NORDTEST checklists)Certificates, Approvals and Statements.HW Test SheetsObject Test Report / Sheets Application Test ReportNode to node communication Test SheetsTest Reports for Test of Serial LinksPunch log

DocumentationNORSOK Z-015:

1. Overall frame GA‘s.2. All junction box/enclosure GAs.3. Hydraulic Schematic Diagram if applicable.4. Electrical Schematic Diagram.5. Any Mimic Panel Drawings.6. System Block Diagram.7. Electrical Interconnection Diagrams and/or cable

schedules for all system/subsystems.8. Tubing Diagram if applicable.9. Operations Manuals for all system/subsystems.10. Maintenance Manuals for all system/subsystems.11. Recommended spares for all system/subsystems.12. Certification for all systems/subsystems including but not limited to:-

Hazardous area inspection schedule.Instructions for safe use.Special conditions of use.Any calculations to allow correct installation of

equipment in a hazardous area.Hazardous area equipment schedule.

13. EC declaration of conformity for all system/subsystems. (European directive).14. Interface Drawings.15. FAT/SIT procedures.16. Manufacturers and vendor test results for cabling used (IR and continuity).17. Manufacturers and vendor test results fibre cabling.18. All calculations and documentation pertaining to the achieved SIL rating.

DocumentationNode book:

Documentation of relevant documents:

- Design documents and drawings- Specifications- Procedures- Change logs- Test reports

Purpose:

- System documentation- Conformity- Traceability

DocumentationOther relevant activities:

- QA plan and QA activity list - Documentation review (Spec/C&E)- Technical reviews, HW, SW and HMI- Configuration Review- Participation in HAZID/HAZOP- Validation of procedures FAT/IAT- Internal Roxel procedures

- Experience transfer

Instrumentation

Ea 8-23°

General:• All sensors SIL 2 (not Gamma), exd, exi

• Flow• Level• Temp.• Pressure• Mass

• Prosess Connection in SS316 (wet parts)• All type Signals incl.

• 4-20mA• Field bus (FF, PA, Hart)

• All sensors can be delivered w/options• Housing (ss 316)• Hasteloy c, titan, monel (wet parts)• Diagnostics tool kit

Valves and actuators

General:• SIL 2, exd, exi, exm,

• Prosess Connection in brass, SS316 (wet parts)• Signals that can be provided

• 3-15 psi• 4-20mA• Field bus (PA, AS)• «most common supplies» (AC/DC)

• Can be delivered w/options• Housing (ss 316)• Hasteloy c, titan, monel (wet parts)