Introduction to The SafetySIL Emergency Shutdown Block Valve System

transcript

Revolutionizing the way the Process, Production

& Pipeline Industries Deal with

Safety Critical Systems

SafetySIL

Revolutionizing the way the Oil Field Industries Deal with Safety Critical Systems

WELCOME

To the World’s First & Only

On-Line, Fault-tolerant, Full-Stroke Testing

Emergency Shutdown Block Valve System

Revolutionizing the way the Oilfield Industries Deal with Safety Critical Systems

SafetySIL

INTRODUCING: THE SafetySIL BLOCK VALVE SYSTEM

U. S. Patent No. 6,058,956

Revolutionizing the way the Oilfield Industries Deal with Safety Critical Systems

SafetySIL

Revolutionizing the way the Oil Field Industries Deal with Safety Critical Systems

Applying the SafetySIL

Regulatory Oversight

Operator’s Risk Strategy

Safety Integrity Level (SIL)

Revolutionizing the way the Process Industries Deal with Safety Critical Systems

REQUIRES OPERATORS OF HAZARDOUS PROCESSES TO:

• IDENTIFY AND MITIGATE ALL POTENTIALLY DANGEROUS EVENTS

• DANGEROUS EVENTS IMPACT SAFETY, HEALTH, AND THE ENVIRONMENT

THEY ARE REQUIRED THEN TO EITHER:

• REDUCE THE CONSEQUENCES IF THESE EVENTS OCCUR

• REDUCE THE PROBABILITY OF THEIR OCCURANCE TO A LEVEL DEEMED

“ACCEPTABLE.”

SafetySIL

FEDERAL & STATE REGULATORY OVERSIGHT

SafetySIL

OPERATORS RISK STRATEGY

PROCESS HAZARD ANALYSIS (PHA) CONSISTS OF:

• STUDYING THE PROCESS

• REDUCING THE PROBALILITY OF A DANGEROUS EVENT

• REDUCING THE RISK TO THE REQUIRED “ACCEPTABLE” LEVEL

• SAFETY INSTRUMENTED SYSTEMS (SIS) ARE INSTALLED TO REDUCE RISK

• SIS ARE ASSIGNED A SAFETY INTEGRITY LEVEL (SIL)

SafetySIL

SAFETY INTEGRITY LEVEL (SIL)

BASED ON (3) CHARACTERISTICS OF THE PROCESS AND SIS:

1. SHUTDOWN DEMAND RATE

2. PROBABILITY TO FAIL UPON DEMAND (PFD)

3. TESTING FREQUENCY

EACH OF THESE FACTORS CAN BE ADDRESSED TO INCREASE THE SIL OF A SIS

SafetySIL

INCREASING SIL

ACTIVITIES THAT CAN RESULT IN A HIGHER SIL FOR A SIS:

• RE-ENGINEERING PROCESS TO LOWER THE SHUTDOWN DEMAND RATE

• INCREASE MEAN TIME BETWEEN FAILURE (MTBF) OF SIS EQUIPMENT

• TEST SIS MORE FREQUENTLY

SafetySIL

SIL =Testing Frequency

(PFD X Demand Rate)

SIL RELATIONSHIP DEFINED

TESTING FREQUENCY ↑ = SIL ↑

PDF ↓ = SIL ↑

DEMAND RATE ↓ = SIL ↑

SafetySIL

FREQUENCY TESTING

EFFECTS SIL IN THE FOLLOWING WAYS:

• ANY SYSTEM CAN MEET REQUIRED PFD IF IT IS TESTED FREQUENTLY ENOUGH

• FREQUENT FUNCTION TESTING CAUSES PROCESS INTERUPTIONS

• PROCESS INTERUPTIONS REDUCE PRODUCTION & REVENUE

• PARTIAL STROKE TESTING DECREASES INTERUPTIONS, BUT ALSO DIAGNOSTIC

COVERAGE

SafetySIL

SIL LEVELS DEFINED

RANGES OF (4) LEVELS OF SAFETY INTEGRITY (IEC 61508):

•SIL 1 : 0.1 – 0.01 Failures / YR (1% to 10% or RRF 10-100 YRS)

•SIL 2 : 0.01 – 0.001 Failures / YR (0.1% to 1% or RRF 100-1,000 YRS)

•SIL 3 : 0.001 – 0.0001 Failures / YR (0.01% to 0.1% of RRF 1,000-10,000 YRS)

•SIL 4 : 0.0001 – 0.00001 Failures / YR (0.001% to 0.01% or RRF 10,000-100,000 YRS)

(Note: Administrative Procedures/Operator Actions are classed as SIL-1)

(Interesting Note: Safety Integrity Level is the same as the number of zeros)

SafetySIL

CONTRIBUTIONS TO SIS FAILURES OF THE

FINAL CONTROL ELEMENT (BLOCK VALVE):

• MAJORITY OF DANGEROUS FAILURES CAUSED BY THE BLOCK VALVE

• MAJORITY OF NUISANCE TRIPS CAUSED BY THE BLOCK VALVE

• PRIMARY CHALLENGE IS FREQUENCY TESTING THE BLOCK VALVE

• ACHIEVING NEAR 100% DIAGNOSTICS WOULD SHUT DOWN THE PROCESS

• TESTING SYSTEMS CAN CAUSE COSTLY SPURIOUS/NUISANCE TRIPS

Note: Dangerous Failures are classed under “Probability to Fail on Demand” (PDF),

Nuisance (spurious) Trips are classed under “Mean Time To Fail Safe” (MTTFS)

SafetySIL

SIS SYSTEM DESIGN

WHEN DESIGNING A SIS:

• USE EQUIPMENT WITH A LARGE MTBF (DOESN’T FAIL OFTEN)

• DESIGN FOR INCREASED TESTING FREQUENCY TO ACHIEVE THE PFD

• MOST VULNERABLE PART OF THE SIS IS THE FINAL ELEMENT

(THE BLOCK VALVE)

LATEST SIS DESIGNS FOR BLOCK VALVES DO NOT SOLVE THE PROBLEM

SafetySIL

SIS BLOCK VALVE DESIGN

TWO (2) BLOCK VALVES IN SERIES:

• INCREASE SAFETY WITHOUT THE NEED TO TEST MORE FREQUENTLY

• UNLIKELY THAT BOTH VALVE’S WILL HAVE FAILED AT THE SAME TIME

• DOUBLES THE CHANCE FOR A SPURIOUS/NUISANCE TRIP

• SIGNIFICANT POTENTIAL FOR LOST REVENUE,

(COULD BE MORE COSTLY THAN OTHER ALTERNATIVES)

SafetySIL

SIS BLOCK VALVE DESIGN

PARALLEL BYPASS AROUND THE BLOCK VALVE:

• ALLOWS FOR ON-LINE FULL STROKE TESTING

• INCREASES DIAGNOSTIC COVERAGE OF EACH TEST

• HUMAN ERROR ON BYPASS CREATES POTENTIAL FOR DANGEROUS FAILURE

• LIMITED TO SIL 1 RATING (BECAUSE OF THE HUMAN INTERACTION)

SafetySIL

SIS BLOCK VALVE TESTING

PARTIAL STROKE TESTING:

• BLOCK VALVE IS EXERCISED PARTIALLY CLOSED

• TEST PERFORMED WITH MINIMAL PROCESS INTERUPTION

• DECREASED DIAGNOSTIC COVERAGE VS. A FULL STROKE TEST

• WIDELY ACCEPTED THAT PARTIAL STROKE WILL CATCH 60 – 80% OF

FAILURES, BUT WHAT ABOUT THE OTHER 20 – 40%?

SafetySIL

SafetySILThis screen print from a large, international partial stroke testing manufacturer shows their

opinion of Partial Stoke Technology!

SafetySIL

INDUSTRY NEEDS A BLOCK VALVE SYSTEM CAPABLE OF:

• ON-LINE TESTING

• FULL STROKE TEST

• FAULT TOLERANT (NO SPURIOUS/NUISANCE TRIPS, REPAIRABLE ON-LINE)

• SIL CAPABLE

• NO PROCESS INTERUPTION, REGARDLESS OF THE TESTING FREQUENCY!!!

SafetySIL

THE SafetySILWHY’S:

SafetySIL

THE SafetySILWHY’S

WHY DOES THE SafetySIL INCREASE THE LEVEL OF PROTECTION:

• ON-LINE, FULL STROKE TESTING

• TESTING AS FREQUENTLY AS REQUIRED TO ACHIEVE ANY SIL, EVEN SIL 4

• NEARLY 100% DIAGNOSTICS, INCLUDING OPERATION OF PLC & I/O MODULES

• NO PROCESS INTERUPTION, REGARDLESS OF THE TESTING FREQUENCY!!!

SafetySIL

WHY DOES THE SafetySIL DECREASE NUISANCE TRIPS:

• FAULT TOLERANT TESTING SYSTEM

• TESTING WILL DETERMIME IF THERE IS ANY FAILED PART THAT WILL

PREVENT EXPECTED OPERATION

• FAILED PART CAN BE REPAIRED ON-LINE WITH NO PROCESS INTERUPTION

• SPURIOUS/NUISANCE TRIP WILL NOT INTERUP PROCESS

SafetySIL

WHY DOES THE SafetySIL SAVE YOUR OPERATIONS MONEY:

• ELIMINATING SPURIOUS/NUISANCE TRIPS

• A TYPICAL SPURIOUS TRIP RATE (STR) CAN BE 3 – 4 PER YEAR

• PREVENTION OF JUST (1) SPURIOUS TRIP CAN PAY FOR THE SYSTEM

• EACH ADDITIONAL SPURIOUS/NUISANCE TRIP PREVENTED IS PURE PROFIT!

SafetySIL

WHY DOES THE SafetySIL DECREASE MAINTENANCE COSTS:

• BLOCK VALVES CAN BE TESTED WHILE IN OPERATION

• NO NEED TO REMOVE A VALVE UNTIL IT FAILS (RUN TO FAIL)

• ON-LINE TESTING INSURES THE VALVE’S ARE FUNCTIONING AS EXPECTED

• REDUCTION IN MAINTENANCE COSTS ARE PURE PROFIT!

SafetySIL

WHY DOES THE SafetySIL DECREASE T-I-Cs:

• COSTS UPWARDS OF $30K TO $35K TO MOVE ONE SAFETY FUNCTION FROM

SIL-1 TO SIL-2, OR FROM SIL-2 TO SIL 3. (MOVING FROM SIL-1 TO SIL 3 CAN

COST UP TO $70K. ONE SafetySIL FUNCTION CAN PROVIDE SIL-4

• ELIMINATES NEED FOR MULTIPLE SIL-1 LAYERS OF PROTECTION

• CAN USE LESS EXPENSIVE VALVES AND OTHER EQUIPMENT (LOWER

MTBFS)

SafetySIL

THE ONLY:

ON-LINE

FULL STROKE TESTING

FAULT TOLERANT

SIL CAPABLE

BLOCK VALVE SYSTEM

THE REVOLUTION IN FAULT TOLERANT TECHNOLOGY!

Revolutionizing the way the Process, Oilfield & Pipeline Industries Deal with Safety Critical Systems

SafetySIL

SafetySIL, LLC’s PARTNER

IN PRODUCTION, FACTORY ACCEPTANCE TESTING AND

FIELD SUPPORT FOR

• INSTALLATION,

• CONFIGURATION

• MAINTENANCE

• TRAINING

Introduction to The SafetySIL Emergency Shutdown Block Valve System

Engineering