T57 - Process Safety and Critical Control What Solution Best Meets Your Needs?

Transcription

1 PUBLIC CO900H T57 - Process Safety and Critical Control What Solution Best Meets Your Needs? PUBLIC

2 PUBLIC Agenda Introduction To Process Safety Process Safety and Machine Safety Things to Consider When Choosing Rockwell Automation and Critical Control Questions

3 PUBLIC Copyright 2015 Rockwell Automation, Inc. All 3 Rights Reserved. Introduction of Presenter Stefan Mizera, Eng. ISA 84 SIS Fundamentals Specialist Product Manager of Rockwell Automation Process Safety Products: AADvance Control System and Trusted Control System since 2013 In the automation industry since 1998 Bachelor of Electrical Engineering Power and Control Systems ISA member since 2005

4 PUBLIC Agenda Introduction To Process Safety Process Safety and Machine Safety Things to Consider When Choosing Rockwell Automation and Critical Control Questions

5 PUBLIC 5 Introduction to Process Safety Terminology - BPCS and SIS Safety Instrumented System (SIS) Basic Process Control System (BPCS) A system composed of sensors, logic solvers, and final control elements for the purpose of taking the process to a safe state when pre-determined conditions are violated. I/P PT 1A PT 1B A system that responds to input signals from the equipment under control and/or from an operator and generates output signals, causing the equipment under control to operate in the desired manner.

6 Introduction to Process Safety What is Process Risk? PUBLIC 6 Plant and Emergency Response Emergency response layer Mitigate Containment Passive protection layer Prevent Relief valve, Rupture disk Safety Instrumented System Operator Intervention Basic Process Control System Emergency Shut Down Process Shutdown Process Control Normal behavior Active protection layer Pressure Relief Safety layer Trip point Process control layer Process alarm Process control layer

7 Introduction to Process Safety What Standards Apply PUBLIC 7 International Standards IEC Functional safety of electrical/electronic/ programmable electronic safetyrelated systems IEC Functional safety Safety instrumented systems for the process industry sector North American Standards NFPA 85 Burner Management (Boilers, HRSGs, Stokers, etc.) ANSI/ISA (IEC Mod) Functional Safety: Safety Instrumented Systems for the Process Industry Sector API RP 14C Safety Systems for Offshore Production Platforms Reference Documents CCPS Guidelines for Safe Automation of Chemical Processes

8 Introduction to Process Safety It is all about Tolerable Risk BPCS PUBLIC Tolerable Risk 1 fatality in years

9 Introduction to Process Safety Safety Function PUBLIC Safety Function: Close the valve if the pressure reaches a certain limit value PT 1A PT 1B Safety Instrumented System (SIS) Inputs Outputs Safety Integrity Level (SIL) is defined as a relative level of riskreduction provided by a safety function, or to specify a target level of risk reduction. In simple terms, SIL is a measurement of performance required for a Safety Instrumented Function (SIF). T-1 SDV 1 S

10 Introduction to Process Safety Safety Integrity Levels Safety Integrity Level Probability of Failure on Demand (PFD) Risk Reduction Factor (1/PFD) Safety Availability (1-PFD) to <.0001 > 10,000 to 100,000 > to to <.001 > 1,000 to 10,000 > 99.9 to to <.01 > 100 to 1,000 > 99 to to <.1 > 10 to 100 > 90 to 99 0 Control (N/A) PUBLIC For Low Demand Mode of operation Performance requirements, not detailed implementation requirements

11 Introduction to Process Safety Hardware Fault Tolerance PUBLIC 11

12 Introduction to Process Safety Control System Incidents Changes After Commissioning 20% Operations & Maintenance 15% Installation & Commissioning 6% Design & Implementation 15% Incorrect & Incomplete Specification 44% Out Of Control - A compilation of incidents involving control and safety systems by the UK Health & Safety Executive PUBLIC Functional safety standards address all these issues

13 PUBLIC Agenda Introduction To Process Safety Process Safety and Machine Safety Things to Consider When Choosing Rockwell Automation and Critical Control Questions

14 Process Safety and Machine Safety Different standards - Process PUBLIC 14

15 Process Safety and Machine Safety Different standards - Machinery PUBLIC 15

16 PUBLIC Agenda Introduction To Process Safety Process Safety and Machine Safety Things to Consider When Choosing Rockwell Automation and Critical Control Questions

17 Things To Consider When Choosing Types of Questions we Ask What is the Target SIL level or SIL levels in single architecture? SIL 1, Low Integrity; SIL 2, Medium Integrity; SIL 3, High Integrity What Levels of Fault Tolerance are Required? Fail-Safe (Simplex), Fault Tolerance (Dual or Triplicated) What level of Integration with the Control Platform (BPCS) is required? Separate & Diverse Logic Solvers, Common Logic Solvers PUBLIC Centralized or distributed safety Central Processing, Remote I/O; Central Engineering Interface, Distributed Processing 3rd party communication & device interfaces Smart Devices (HART); 3 rd Party Logic Solvers (DCS or PLC) 17

18 PUBLIC Agenda Introduction To Process Safety Process Safety and Machine Safety Things to Consider When Choosing Rockwell Automation and Critical Control Questions

19 Rockwell Automation and Critical Control ControlLogix I/O OK RUN BAT RUN I/O RUN RS-232 OK BAT RUN PRI COM OK REM PROG CHA CHB OK PRI COM OK REM PROG CHA CHB OK Targeted for applications where customers who prefer a single architecture Key Features: Safety Add-On Instruction Integrated Control & Safety I/O on EtherNet/IP Up-to-date with Logix releases Supports fail-safe and fault tolerant configurations A Quality Allen Primary A-B Quality Allen-Bradley Secondary Common, Fault Tolerant/Fail Safe, SIL 2 PUBLIC 19 ControlNET Redundancy Module Logi x555 A 5 # 0 1 ControlNet Redundancy Module Logi PRIM x555 A 5 # 0 1

20 Rockwell Automation and Critical Control AADvance Targeted for applications that require a flexible architecture, distributed safety and mixed SIL Levels Key Features: Simplex (1oo1D), Dual (1oo2D) or TMR (2oo3) processor and I/O architectures Stand alone or part of a large distributed network Supports CIP connectivity to PlantPAx All 5 IEC programming languages Comprehensive diagnostics and self-test Scalable fault-tolerance and safety at module level Fully fault-tolerant Ethernet networks for safety HART Support for Field Device Diagnostics & Maintenance (HART pass through). Interfaced, Fault Tolerant/Fail Safe, SIL 2 & 3 PUBLIC 20

21 Rockwell Automation and Critical Control AADvance Simplex SIL2 PUBLIC 21 1oo1D Fail-Safe Certified for use in SIL2 applications TA TA I/P CPU O/P

22 Rockwell Automation and Critical Control AADvance Simplex SIL2 PUBLIC 22 CPU Base with one CPU populated I/O Base with one input and one output fail-safe

23 Rockwell Automation and Critical Control AADvance Simplex SIL3 PUBLIC 23 1oo1D/1oo2D Fail-Safe Certified for use in SIL3 applications TA TA CPU O/P I/P CPU O/P

24 Rockwell Automation and Critical Control AADvance Simplex SIL3 PUBLIC 24 Redundant CPUs

25 Rockwell Automation and Critical Control AADvance Redundant SIL3 PUBLIC 25 1oo2D/2oo3 Fault Tolerant Certified for use in SIL3 applications TA TA CPU O/P I/P CPU O/P

26 PUBLIC 26 Rockwell Automation and Critical Control AADvance Redundant SIL3 Redundant CPUs Redundant Terminations Redundant inputs Redundant outputs

27 Rockwell Automation and Critical Control AADvance TMR SIL3 PUBLIC 27 SIL3 TMR Fault Tolerant applications TA TA CPU O/P I/P CPU O/P

28 PUBLIC 28 Rockwell Automation and Critical Control AADvance TMR SIL3 Triplicated CPUs Triplicated Terminations Triplicated inputs Fault Tolerant outputs

29 PUBLIC 29 Rockwell Automation and Critical Control Trusted TMR Targeted for applications that require a High Availability TMR architecture or have very high I/O counts. Key Features: Extensive 2oo3 (2 out of 3) voting throughout architecture Extensive diagnostics and triplication provides high safety, fault-tolerance & high availability High density 40 channel TMR I/O modules CIP connectivity to PlantPAx Supports 1000 s of I/O with a single TMR processor Partial Stroke testing part of standard product offering All 5 IEC programming languages Fully fault-tolerant Ethernet networks for safety Interfaced, Fault Tolerant, SIL 3

30 PUBLIC Agenda Introduction To Process Safety Process Safety and Machine Safety Things to Consider When Choosing Rockwell Automation and Critical Control Questions

31 Questions? Thank You! PUBLIC