vanBeurden-IntegrationofSafetyLifecycleTools-EXIDA

Standards

Certification

Education & Training

Publishing

Conferences & Exhibits

Integration of Safety Lifecycle Tools and PLC Programming

Iwan van Beurden, exida

Charlie Fialkowski, Siemens

2

Presenters & Co-authors

• exida– Iwan van Beurden, MSc, CFSE

– Senior Safety Engineer

– exSILentia product Manager

• Siemens– Charlie Fialkowski, CFSE

– Safety System Product Manager

– John Cusimano, CFSE – Business Development Manager, Process Safety Systems

– Patricia Ela

3

Integration of Safety Lifecycle Tools and PLC Programming

• Safety Lifecycle Phases• Example HIPPS• Safety Lifecycle Engineering Tools

– SIL Selection– SIL Verification (conceptual design)– Cause & Effect Matrix (detailed design)

• Integration of exSILentia and Safety Matrix

4

ANSI/ISA 84.00.01-2004 Safety Lifecycle

Management of Functional Safety and Functional

Safety Assessment

Clause 5

Safety Lifecycle Structure

and Planning

Sub-clause

6.2

Verification

Sub-clause 7, 12.7

Management of Functional Safety and Functional

Safety Assessment

Clause 5

Safety Lifecycle Structure

and Planning

Sub-clause

6.2

Verification

Sub-clause 7, 12.7

Risk Analysis and Protection Layer DesignSub-clause 8

Allocation of Safety Functions to Safety Instrumented Systems or Other Means of Risk ReductionSub-clause 9

Allocation of Safety Functions to Safety Instrumented Systems or Other Means of Risk ReductionSub-clause 9

Safety Requirements Specification for the Safety Instrumented SystemSub-clause 10

Design and Development of Safety Instrumented SystemSub-clause 11

Design and Development of Safety Instrumented SystemSub-clause 11

Design and Development of Other Means of Risk ReductionSub-clause 9

Design and Development of Other Means of Risk ReductionSub-clause 9

Installation, Commissioning, and ValidationSub-clause 14Installation, Commissioning, and ValidationSub-clause 14

Operation and MaintenanceSub-clause 15Operation and MaintenanceSub-clause 15

ModificationSub-clause 15.4

DecommissioningSub-clause 16

ANALYSIS

REALIZATION

OPERATION

5

Example HIPPS Safety Instrumented Function

• Example Process– Heat used to separate

petroleum into various components in distillation column

• Hazard identified– Column C-51 Overpressure,

with Possible Overloading of Flare System

• Safety Instrumented Function– High Pressure on Column C-

51 Causes Steam Supply to Reboiler E-52 to Close

6

SIL Selection

SIF Item Hazard Description Inputs Outputs Target SIL

SIF 1 Column C-51 overpressure, with

possible overloading of flare system.

High Pressure on Column C-51 causes Steam Supply to

Reboiler E-52 to close.

PT-51PT-52PT-53

(2oo3)

XV-51 CloseXV-52 Close

(1oo2)

3

Note: Target SIL and input / output voting are for illustrative examples only and are not to be taken as typical, suggested or recommended.

Assume• Demand frequency

– Over pressure every 3 years

• Consequence– Single Fatality

– Economic Loss of $4 Million

7

Conceptual Design (I)

PT-51

PT-52

PT-53

2oo3

Logic Solver

S S

1oo2

SIF Item Hazard Description Inputs Outputs Target SIL

SIF 1 Column C-51 overpressure, with

possible overloading of flare system.

High Pressure on Column C-51 causes Steam Supply to

Reboiler E-52 to close.

PT-51PT-52PT-53

(2oo3)

XV-51 CloseXV-52 Close

(1oo2)

3

Note: Target SIL and input / output voting are for illustrative examples only and are not to be taken as typical, suggested or recommended.

XV-51 XV-52

8

Conceptual Design (II)

9

Detailed DesignLegend:O = OpenC = ClosedR = ResetA = Action1 = See Note 1 (and so on)SD = Shutdown (Stop)P = Permissive

Tag

FC

V-0

01

HV

-001

HV

-002

Tag Description Vote EULO EUHI Units Trip Act 1 2 3 4 5 6 7 8 9 10 11 12 13 14 151 FSLL-001 Flashed crude to B-2A Heater Pass 1 Lo-Lo Flow 1oo1 C2 FSLL-002 Flashed crude to B-2A Heater Pass 2 Lo-Lo Flow 1oo1 C34 HS-001 B-2A Heater Fuel Gas Control Valve Minimum Firing SW 1oo1 C5 HS-002 B-2A Heater Fuel Gas Block Valve Dropout SW 1oo1 C6 HS-003 B-2A Heater Pilot Gas Block Valve Dropout SW 1oo1 C789

1011121314151617181920

Rev Date B y App

0 17-May-06 xx yy

Project No. Page of Rev

xxx 1 1 0

Item: 1

Cause o

r Effect

Tag: I-1ADescription: B-2A Heater Shutdown

(1) Reference P&ID: xxx

Description

B-2

A H

eate

r Fue

l Gas

Con

trol

Val

ve (M

inim

um F

ire) (2

)

B-2

A H

eate

r Fue

l Gas

Blo

ck V

alve

B-2

A H

eate

r P

ilot G

as B

lock

Val

ve

Input or Cause

Switch delay of 3 Seconds on the input.Switch delay of 3 Seconds on the input.

Notes: Description

Under Development

(2) Minimum firing: de-energize relay to interrupt 4-20 mA signal from FC-001(3) Restores FC-001 control.

Client: By:

SIS Functional Specification

C&E 001

Drawing No.

xxx

10

exSILentia to Safety Matrix Integration Workflow

project.exiexSILentia export file

exSILentiato

Safety Matrix Utility

11

SIMATIC Safety Matrix for HIPPS Example

12

The Safety Lifecycle - Objectives

• Build safer systems that do not experience as many of the problems of the past

• Build more cost effective systems that match design with risk

• Eliminate “weak link” designs that cost much but provide little

• Provide a global framework for consistent designs

13

Summary

• The ANSI/ISA 84.00.01-2004 (IEC 61511 Mod.) offers the opportunity to design safer systems and optimize cost

• Safety Lifecycle implementation can be engineering and documentation intensive

• Various software tools address different phases of the Safety Lifecycle

• exSILentia covers SIL selection, SIL verification and reliability calculations

• SIMATIC Safety Matrix is a Cause and Effect Matrix design, programming, and operations and maintenance tool

• Import utility provides a comprehensive cost effect and less error prone solution for managing the entire Safety Lifecycle

14

Path Forward

• Standardize a conceptual design to detailed design transition format

Standards

Certification

Education & Training

Publishing

Conferences & Exhibits

Integration of Safety Lifecycle Tools and PLC Programming

Iwan van Beurden, exida

Charlie Fialkowski, Siemens