T72 - Process Safety and Safety Instrumented Systems
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1 T72 - Process Safety and Safety Instrumented Systems Comprehensive Solutions Portfolio for Fail-Safe to TMR Safety Applications PUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved. 1
2 Agenda Introduction To Process Safety Process Safety and Machine Safety Things to Consider When Choosing Rockwell Automation and Critical Control Questions PUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved. 2
3 Agenda Introduction To Process Safety Process Safety and Machine Safety Things to Consider When Choosing Rockwell Automation and Critical Control Questions PUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved. 3
4 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. PUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved. 4
5 Introduction to Process Safety What is Process Risk? Plant and Emergency Response Emergency response layer Mitigate Containment Passive protection layer Prevent Relief valve, Rupture disk Safety Instrumented System Operator Intervention Emergency Shut Down Process Shutdown Active protection layer Pressure Relief Safety layer Trip point Process control layer Basic Process Control System Process Control Normal behavior Process alarm Process control layer PUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved. 5
6 Introduction to Process Safety What Standards Apply 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 PUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved. 6
7 Introduction to Process Safety It is all about Tolerable Risk BPCS Tolerable Risk 1 fatality in years PUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved. 7
8 Introduction to Process Safety Safety Function 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 PUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved. 8
9 SIL is a Way to Quantify Risk Example Risks Hazards/Safety Security Environment Economic/PR How Bad? RISK reduction How Likely? How Often? Same hazard different location Consequences Chances Frequency PUBLIC Copyright 2018 Rockwell Automation, Inc. 9 All Rights Reserved. 9
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) For Low Demand Mode of operation Performance requirements, not detailed implementation requirements PUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved. 10
11 Introduction to Process Safety Hardware Fault Tolerance PUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved. 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% Functional safety standards address all these issues Out Of Control - A compilation of incidents involving control and safety systems by the UK Health & Safety Executive PUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved. 12
13 Industry Sectors - % of Process Safety Spend Oil & Gas (30%) Refining (19%) Petro Chemical (19%) Power (18%) Chemical (15%) * Information source IHS Technology 2015 PUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved. 13
14 Agenda Introduction To Process Safety Process Safety and Machine Safety Things to Consider When Choosing Rockwell Automation and Critical Control Questions PUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved. 14
15 Process Safety and Machine Safety Different standards - Process PUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved. 15
16 Process Safety and Machine Safety Different standards - Machinery PUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved. 16
17 Agenda Introduction To Process Safety Process Safety and Machine Safety Things to Consider When Choosing Rockwell Automation and Critical Control Questions PUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved. 17
18 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 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) PUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved. 18
19 Agenda Introduction To Process Safety Process Safety and Machine Safety Things to Consider When Choosing Rockwell Automation and Critical Control Questions PUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved. 19
20 Rockwell Automation and Critical Control ControlLogix and 1715 Targeted for applications where customers prefer a single/common 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 Common, Fault Tolerant/Fail Safe, SIL 2 PUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved. 20
21 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 Structured Text, FBD, and Ladder Diagram for Safety Comprehensive diagnostics and self-test Compiler Verification Tool Integrated Version Source Control HART Support for Field Device Diagnostics & Maintenance (HART pass through). Modular, Distributed, Fault Tolerant/Fail Safe, SIL 2 & 3 PUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved. 21
22 Rockwell Automation and Critical Control OptiSIS Targeted for applications that require a Packaged and Configurable SIS Key Benefits and Features: Based on AADvance modules Shorter lead-times, rapid deployment Quick installation, easy upgrades Minimized risk, lower installed costs Configurable (no programming required) Ready-to-install TUV-certified HW and validated SW Connectivity to smart field devices and asset management systems Meets SIL 3 requirements Configurable, Fault Tolerant/Fail Safe, SIL 2 & 3 PUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved. 22
23 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 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 Supports V DC or 120V I/O modules Supports performance levels required for Turbo Machinery Control Wide range of modules meeting SIL3 Centralized, Fault Tolerant, SIL 3 PUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved. 23
24 Process Safety Information available SIS BROCHURE PROCESS SAFEBOOK SIS PRODUCT PROFILES PUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved. 24
25 Agenda Introduction To Process Safety Process Safety and Machine Safety Things to Consider When Choosing Rockwell Automation and Critical Control Questions PUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved. 25
26 Thank You! PUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved. 26
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