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2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators · 1
SIL in de praktijk (Functional Safety)23.04.2015 - Antwerpen
SAMSON AGDr. Thomas Karte
61508 Compliance of Actuatorsand Life Cycle Considerations
2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 2
� Applied Physics, University of Heidelberg, Germany� Occupied in the Industry since 1985, general area of field instrumentation, later
specialist in pneumatic instrumentation for valves in the process industry� Joined SAMSON in 2003, since then engaged in Functional Safety� Current position: Head of department for Innovation Management and Patents� Member of VDI-GMA 6.13, Functional Safety, DKE 9.14, IEC TC65 – WG 13� Numerous articles and patents
Dr. Thomas KarteSAMSON AG, Frankfurt, Germany
+49 69 4009 2086 tkarte@samson.de
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� Main task - Change of Material Flows� Increasing Diagnosis and Asset Management Functions
Control Elements - Complex Field Devices
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Standard questions and concerns
� Certificate for the device / final element in question
� What is the failure rate
� What is the value for diagnostic coverage
� How can evidence of these numbers be given
� What is the usefull lifetime
� Please, I want to have a SIL 3 valve
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Requirement for subcomponent selection
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Structure of talk
� Causes of Valve Failures
� Exclusion of Systematic Errors – Manufacturer Measures
� Valve Testing
� Design and Implementation of Automated Testing
� Numerical Rating
� Summary
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DIN EN 61511 in a nutshell
Failures
Aviodable in principle Unaviodable in principle
Random failuresSytematic failures
FSM-System
Not avoided
�DiagnosticsFail Safe
Redundancy
Probability CalculationDiagnostics
Fail Safediversely Redundancy
✔✔
Measures sufficient?
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Safety Life Cycle to avoid Systematic Errors
�Quelle: DIN EN 61511-1 - Bild 8
Hazard and risk assessment1
Specification of Security? Requirements for the SIS3
Design u.Planung other measures to reduce risk
Design and planning of the SIS4
Decommissioning8
Change7
Operation and maintenance6
Installation, commissioning and validation5
Step 5
Step 4
Step3
Step 2
Step 1
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Manage-ment andassessmentof thefunctionalsafetyaudits
Manage-ment andassessmentof thefunctionalsafetyaudits
10
Manage-ment andassessmentof thefunctionalsafetyaudits
10
Verifi-cation
9
Design and planning the Safety-life-cycle
Allocation of safety functions to protectionlayers2
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Main Components of the Final Element
Seat/Disk
Housing
Packing
Seat Ring
Ball
Housing
Globe Valve Ball Valve
SpringMembraneSolenoid valve
Limit Switch
Positioner
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Potential Hazards (VDI 2180-5)
� Fatigue (e.g. Metal Bellows Seal)
� Wear from Cavitation / Flashing
� Abrasion (due to material flowing solids)
� Deposits of the Medium
� Aging: Damage caused by exposure to light and heat, Organic materials such as plastics and elastomers
� Chemical Attack: Damage caused by chemical extraction & decomposition processes
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Actuator Reliability, Is a Constant Failure Rate Mean ingfull?
Electronics
� Statistical Statements on theReliability
� Controlled Environment� Self-Diagnosis� Methods for accelerated Aging
Mechanics
� Macroscopic, accountable System� Media Influence� Environmental Influence� Long term Effects can´t be Accelerated
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1 ISO 9001 Qualified
2 Quality Manual, Primary Process Development
3 Pressure Equipment Directive 97/23/EG
4 Calculation of Pressurized Parts
5 Materials and Supplier Qualification for Pressure Parts
6 Standard Tests to SAMSON- Globe Valves
7 Quality Management installed that keeps track of field performance
8 Adapting the final element to the specific process – valve seizing
Qualifying Procedures - Manufacturer
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Fixed R&D Schedule compliant to ISO 9001
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Pressure Equipment Directive 97/23/EG
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Calculation of Pressurized Parts
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Calculation of Pressurized Parts
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� Supplier Qualification by SAMSON-Specifications� Minimum Requirement 3.1 - Material Certificate according to DIN EN
10204� 100%-Examination of the Pressure-Bearing parts in the Receipt of Goods
Materials and Supplier Qualification for Pressure Parts
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Standard Test to SAMSON Globe Valves
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Valve Seizing
� Collection of Customer Data in Accordance with DIN EN 60534-7� Collection of additional Information by Echange with Customers� Creating a TV-SK (special design) if necessary
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Valve Seizing –Permissible Flow Velocities
�Supercritical Relaxation
�10bar to 2,5bar
�UVC > Ma1
�Subcritical Relaxation
�10bar to 7bar
�UVC < Ma1
�Critical Relaxation
�10bar to 5bar
�UVC = Ma1
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�Quelle: DIN EN 61511-1 - Bild 8
Hazard and risk assessment1
Allocation of safety functions to protectionlayers2
Specification of Security? Requirements for the SIS3
Design u.Planung other measures to reduce risk
Design and planning of the SIS4
Decommissioning�8
Change�7
Operation and maintenance6
Installation, commissioning and validation5
�Stufe 5
Step 4
Step3
Step 2
Step 1
�11
Management andassessmentof thefunctionalsafety audits
Management andassessmentof thefunctionalsafety audits
�10
Management andassessmentof thefunctionalsafety audits
�10
Verifi-cation
�9
Safety Lifecycle to Avoid Systematic Errors
• Periodic inspection and testing• Examination during operation• Documentation system failure
Validation
Design and planning the Safety-life-cycle
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Safety life cycle at customer side
� Specification of safety requirements
� Selection of suitable components
� Manufacturer declaration
� Valve seizing (fit to the specific process)
� Proven in use statement highly recommended (NE 130)
� Consideration on reliability
� Defined procedures for inspection and testing
� Trained personal
� Documentation of all steps
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What is the safety requirement
� The final element shall shut down or open the pipe
� Leakage rate
� Time response
� Keep specifications as wide as possible
� This has major influence on testing and diagnostic
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Namur recommendation NE 130 „Proven in use“
• NE 130 provides clear
definition for
„proven in use“
• Instrument
performance for a
specific application is
rated
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Failure rates provided by NE 130
� Based an data generated by NE 93
� Survey on a voluntary basis within NAMUR companies
� Applicable for proven in use devices
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Process equipment datasheet (VDI 2180 – Part 5)
• Valve seizing process
to adapt to specific
application
• Guided by VDI 2180-5
(example)
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How is a Valve Tested
From the Manufacturer
� Items� Leak Test� Pressure Test� Functional Test
In the plant
� Inspection after 61508 (Plant Tour, Visual Inspection) � Functional Test during Non-Operating Times� (Parameters: Function, Closing Time, End Position) � Functional Testing under Load (+ leaks)
Standard requires Testing under Operating Condition s
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3730 Positioner
�Solenoid valve, Limit Switches and Positioners Diagnostic Capability in a Housing
�Diagnostics�Automatic Monitoring
during Operation
Automation Options
3738 Intelligent Limit Switch
� Solenoid Valve, Limit Switches
� Certified Safety Function by TÜV
� Diagnostics� Automatic Monitoring during
Operation
Solenoid Valve, Limit Switches
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• Suitability for Safety-related Circuits
• Shutdown over 4 mA• Reduced Cabling Costs
Positioner as a Single Automation Component
Safety-related Control Positioner
Position Feedback Positioner, Analogue
Pressure Measurement Positioner, Analogue
Automation Valve Test Positioner
Test Coverage Pneumatic yes
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Automated Testing
Result:
� Functional Test � Path-time Diagram� Dead time, run-time� Breakout Force � Exact closed position
ALARM
Reproducible Implementation:
� Valve movement is initiated� Positioner Internal Measurement � of the Valve Motion � Valve Motion is Recorded
Dokumentation:
� Registration of the Event� Numerical Results� Path-time Diagram � Good / Bad Review
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Periodic Inspection
Solution:
� Functional Test � Travel-time Diagram� Dead time, Run-time � Breakout Force � Exact Closed Position
ALARM
Rating:
� Ability to move � Breakout Force � Travel-time� Tightness (from closed position)
Implementation:
� Manually triggered� Automatic test without
user interaction
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Testing During Operation
As an additional Security Measure, or to check during Operation
Result:� Functional Test � Path-time Diagram� Dead time, Run-time� Breakout Force � Exact Closed Position
ALARM
Rating:
� Ability to move � Breakout Force � Travel-time� Tightness (from closed position)
Implementation:
� Manually or automaticallytriggered
� Automatic test withoutuser interaction
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Examination during Operation, Friction Detection
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Capture of spurious trips
Result:
� Functional Test� Travel-time Diagram� Dead time, Run-time� Breakout Force � Exact Closed Position
Alarm
Implementation:
� Triggered by valvemovement
� independent datacollection
Rating:
• Ability to move • Breakout Force • Travel-time• Tightness (from closed position)
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�Bauformen SIL 2 (Final element 50%)
Safety margin
PRTPFD ⋅= λ2
1
0,0000
0,0025
0,0050
0,0075
0,0100
0 6 12 18 24
Prooftest [month]
PFD
PFD
SIL2-Grenze
λ = 1,14-06 Failure rate (1/hr)
TPR = 1 year Proof Test Intervall
Extended Operation Time by Online Testing
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�Bauformen �SIL 2 (Final element 50%)
Safety margin
PRPST TDCTDCPFD ⋅−⋅+⋅⋅= )1(21
21 λλ
PRTPFD ⋅= λ2
1
0,0000
0,0025
0,0050
0,0075
0,0100
0 6 12 18 24
Prooftest [month]
PFD
PFD
PFD PST
SIL2-Grenze
DC = 0,6 Diagnostic coverage
λ = 1,14-06 Failure rate (1/hr)
TPST = 1 month Partial Stroke Intervall
TPR Proof Test Intervall
�PST
Extended Operation Time by Online Testing
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2180-3 ( 3.4.1) and IEC 61511
� Analysis of the records is mandatory� Documentation for the operating experience regarding any problems � Potential for improvement: new devices with more favorable properties � Option to extend the proof time
Optimization of Safety Loops
Aus Paul Gruhn, „Safety Shutdown Systems“
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Error Images and Diagnostic Coverage
Component Failure Mode RecognizabilityDiagnostic Possibility
Positioner
Seat/Disk
Corrosioninternal/external
Flow measurement, diagnosis STR, disassembly
acoustic leak sensor, zero offset (driving force, friction)
Fatigue (e.g. Metal Bellows Seal)
not applicable not applicable
Wear from Cavitation / Flashing
Flow measurement, diagnosis STR, disassembly
acoustic leak sensor, end position trend (Zero Point offset),
(driving force, friction)
Abrasion Flow measurement, diagnosis
STR, disassembly
Deposits of the medium
Flow measurement, diagnosis STR, disassembly
Aging not applicable not applicable
Chemical Attack not applicable not applicable
mechanical stressFlow measurement, diagnosis
STR, disassembly
acoustic leak sensor, end position trend (Zero Point offset),
(driving force, friction)
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Normative Requirements: DefinedProcesses, Documentation, DiagnosticsCoverage
Summary
Safety Life Cycle is supported by state of the art instrumentation
Systematic failures are dominant – as a consequence Safety Life Cycle is the most important isssue
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