Integration of Safety Lifecycle Tools-EXIDA - ISA

offbeatnothingSoftware and s/w Development

Dec 2, 2013 (3 years and 11 months ago)

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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 Design
Sub
-
clause 8
Allocation of Safety Functions to Safety Instrumented
Systems or Other Means of Risk Reduction
Sub
-
clause 9
Allocation of Safety Functions to Safety Instrumented
Systems or Other Means of Risk Reduction
Sub
-
clause 9
Safety Requirements Specification
for the Safety Instrumented System
Sub
-
clause 10
Design and Development of
Safety Instrumented System
Sub
-
clause 11
Design and Development of
Safety Instrumented System
Sub
-
clause 11
Design and Development of
Other Means of Risk
Reduction
Sub
-
clause 9
Design and Development of
Other Means of Risk
Reduction
Sub
-
clause 9
Installation, Commissioning, and Validation
Sub
-
clause 14
Installation, Commissioning, and Validation
Sub
-
clause 14
Operation and Maintenance
Sub
-
clause 15
Operation and Maintenance
Sub
-
clause 15
Modification
Sub
-
clause 15.4
Decommissioning
Sub
-
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
-
51

PT
-
52

PT
-
53


(2oo3)

XV
-
51
Close

XV
-
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
-
51

PT
-
52

PT
-
53


(2oo3)

XV
-
51
Close

XV
-
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 Design

Legend:
O = Open
C = Closed
R = Reset
A = Action
1 = See Note 1 (and so on)
SD = Shutdown (Stop)
P = Permissive
Tag
FCV-001
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
15
1
FSLL-001
Flashed crude to B-2A Heater Pass 1 Lo-Lo Flow
1oo1
C
2
FSLL-002
Flashed crude to B-2A Heater Pass 2 Lo-Lo Flow
1oo1
C
3
4
HS-001
B-2A Heater Fuel Gas Control Valve Minimum Firing SW
1oo1
C
5
HS-002
B-2A Heater Fuel Gas Block Valve Dropout SW
1oo1
C
6
HS-003
B-2A Heater Pilot Gas Block Valve Dropout SW
1oo1
C
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Rev
Date
B y
App
0
17-May-06
xx
yy
Project No.
Page
of
Rev
xxx
1
1
0
Item:
1
Cause or Effect
Tag:
I-1A
Description:
B-2A Heater Shutdown
(1) Reference P&ID: xxx
Description
B-2A Heater Fuel Gas Control Valve (Minimum Fire) (2)
B-2A Heater Fuel Gas Block Valve
B-2A Heater Pilot Gas Block Valve
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.exi

exSILentia export file

exSILentia

to

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