16
Company and Process Overview
As an independent systems integrator, SELLA CONTROLShave developed a strong reputation of proven expertise ininnovative design and engineering for the supply of SafetyInstrumented Systems (SIS) and Control Systems across variousIndustry sectors.
Through our partnerships with key product suppliers and ourunrivalled in-house engineering capabilities, the company offerscomplete best in class, turnkey project capability with thefollowing full lifecycle services:
• Consultancy
• Project Management
• Engineering & Design
• Manufacturing
• Testing
• Commissioning
• Technical Support
• Training
Functional Safety ManagementRisk AssessmentSIL DeterminationSIL VerificationSafety Requirement SpecificationIndependent Functional Safety Assessment (FSA)Third Party Certification
On time delivery of projectsRegular customer contact Agreed milestones to monitor progress
Functional Design Specification Software Requirements SpecificationDetailed Hardware DesignSoftware Development Loop DiagramsTest ProceduresDesign Calculations
Panel Build System BuildSystem Integration
In-house TestingFactory Acceptance TestingSite Acceptance Testing
System InspectionSupport during Start-up
24 hour call out supportUpgrade/ModificationsMaintenance (IEC 61511 life cycle)Proof testing
Hardware/Software Design Maintenance and Servicing Customised Courses
2
Our aim is to be theleading systems integrator, meetingour customers’ expectations for theprovision of cost effective scalablesafety and control solutions and quality service without compromising safetyrequirements, usingour expert engineeringcapability and integration skillsalongside our functional safety expertise.
www.sellacontrols.com
Functional Safety is at theheart of everything we doSafety First
Operating safely callsfor compliance withbest engineeringpractices. This meansfollowing internationallyrecognised standardsthat require a life-cycleapproach to identifying,managing and reducingrisk across all phasesof a safety-criticalproject.
SELLA CONTROLSwork to ensure thatevery aspect of thesafety life-cycle is addressed in a waythat guarantees safeoperation and fullcompliance with regulatory expectations.
SELLA CONTROLS is a founding member of the 61508Association and in 2001 was awarded the first UKAS accreditedSIRA CASS certificate for Functional Safety Management, anaccreditation we have retained ever since. Functional Safety isembedded into our Quality Management System and thisensures the required techniques and measures detailed in IEC61508 and IEC 61511 are applied to all safety critical projects.
3
Our pedigree and historymake SELLA CONTROLSthe logical choice forSafety Instrumented System and FunctionalSafety solutions.
SELLA CONTROLS utilises highly regarded SIS technologyproducts combined with a choice of controls systems, allowingfor total flexibility. The combined system integration andFunctional Safety knowledge of our dedicated team ofengineers enables us to deliver the benefits of a truly integratedcontrol and safety system.
This also ensures independence and avoids the introduction ofcommon cause systematic errors between protective layers.
Integrated Control and Safety Systems
Cyber Protection
SELLA CONTROLS’ procedures fordelivery of projects offer safeguards toclients’ systems and plant against cyberattacks.
Within most engineering solutions,acceptable cyber-security has beenbased on following OEM instructions andsegmenting the Integrated Administrationand Control Systems (IACS) network.SELLA CONTROLS has improved on thisstance with an engineering approachwhich strengthens security withoutimpacting system availability.
SELLA CONTROLS’ approach is to havea competent team of engineers to reviewthe network architecture for vulnerabilities;fully documenting code changes in areview sheet allowing for constant updatesand traceability with the added securityof restricting the configuration of systemsto prevent program reloads while thesystem is online.
Building on an existing and robust ISO9001 Quality System and FunctionalSafety Management System, SELLACONTROLS has developed a SecurityManagement System which closelymonitors the usage of portable devices(and the files contained on them). Secure patch management for softwareapplications and Anti-Virus is achieved byevaluating and approving all necessarypatches to the engineering solution duringmanufacture. This provides our end userswith the assurance that the appropriatecyber-security management is appliedthroughout the duration of a project.
4
PROCESS
BPCS
PSD
HIPPS
ESD
www.sellacontrols.com
SELLA CONTROLS followthe Principles of IEC62443-2-4
5
Project Management
Strong communication is the key to thesuccess of projects and theSELLA CONTROLSproject teams are encouraged to develop strongrelationships withthe client team.
6
SELLA CONTROLS has gained a worldwide reputation forsuccessful project management and delivery. All projects areassigned a dedicated project delivery team, who use our robustin-house project management tools and procedures, in line withour quality management system (approved to BS EN ISO 9001since 1989).
Our engineering team will ensure project milestones are realised and client expectations are exceeded.
www.sellacontrols.com
Functional Safety Consulting
Functional Safety LifecycleServicesThe effective implementation of functional safety standards,practices and processes is increasingly important inensuring that Safety Instrumented Systems areappropriately specified, designed installed and maintained.IEC 61508 and the process sector specific functionalsafety standard IEC 61511 promote the concept of thesafety lifecycle. Experience shows that engaging expertsearly in the design process has a positive impact on projects.
SELLA CONTROLS have over 35 years’ experience in thespecification, design, installation and modification ofsafety critical systems. Our experience spans multipleindustry sectors including Oil and Gas, Petro-chemical,Nuclear and Power.
Our involvement gives you access to our combinedfunctional safety knowledge, competency and our TÜVRheinland Certified Functional Safety Expert (FS-Expert,SIS, ID#260/15).
We can support you by providing expert ledFunctionalSafety services across the entire lifecycle including:
• Functional Safety Management• HAZOP / CHAZOP / FMEA Facilitation• SIL Determination (LOPA, Risk Graph FTA)• Safety Requirements Specification• Full Loop SIL Verification • Proof Test Procedure Development• HIPPS Dossier Management• Independent Functional Safety Assessment
7
Applications
Safety Instrumented System (SIS)
SIS & Emergency Shutdown Systems are used across a widerange of industries and offer personnel, asset and environmentalprotection by means of instantaneous, fai l safe, plantimmobilisation.
SIS is arguably the most widely used safety related applicationin the process industry. By monitoring safety critical fieldinstrumentation the SIS provides automatic preventative action inthe case of unsafe operational parameter deviations and ensuresrapid isolation if loss of containment occurs.
A series of pre-engineered functions will then bring the facilityback into full operation once the cause of the shutdown has beendetermined and dealt with.
By offering programmable and non-programmable solutions,SELLA CONTROLS provides a versatile range of plant protectionup to SIL3 in accordance with IEC 61508 / 61511. Whether theapplication requirement is for a small number of I/O signals or acomplex system consisting of thousands of field devices, SELLACONTROLS has the expertise to design and build a tailored SISto meet client specifications.
Burner ManagementSystems (BMS)
A BMS is required as a safety critical elementon most large burner systems. They managethe safety of start-up, the purge cycle,flame ignition signal, flame detection andany shutdown requirements. BMS canalso incorporate control and monitoring.SELLA CONTROLS offer solutions thatallow the BMS logic solver to be housedeither local to the burners / furnace (evenin zone classified areas) or remote in acentralised control room, with certifiedcommunication channel to other safetyrelated devices. We can also offercommunications to remote or local alarmmanagement and operator displays,where our HMI package can assist withcontrol, diagnostics and performanceanalyses. SELLA CONTROLS can assistwith ensuring BMS controls align with bothEN746 & IEC 61511.
End users requirements and philosophiesvary so SELLA CONTROLS offers anumber of solutions to meet end userBurner Management Systems preferences.These include conf igurat ion withsegregated hardware for each burner, (onmulti burner systems) which helps in themaintenance of the BMS. Alternatively acentralised logic solver with additionaloption using distributed PESs on acommon network can be provided.
8
SIL3 Safety Instrumented Systemscompliant with IEC 61511
Typically, certified pressure transmitters are used in the classic2oo3 configuration for improved Probability of Failure on Demand(PFD) on an interlock manifold or individual block and bleed keyinterlocked assemblies.
Certified logic solvers are either in a single or dual configurationfor increased availability. Equipment can be mounted in classifiedareas deploying; Exn, Exe, Exp and Exd methods for Zone 1or 2.
Valves can be supplied either as single or dual units forincreased safety. The whole system can be TÜV certified foreach individual installation, to meet national and internationalregulatory requirements.
www.sellacontrols.com 9
HIPPSThe High Integrity Pressure ProtectionSystems designed by SELLA CONTROLSprovide increased safety for pipelinesand other critical plant where normaloperation at higher pressures wouldnot be permitted with ordinary SISsystems.
SELLA CONTROLS, with our partners,provide a complete turnkey solutionfor HIPPS, which is IEC 61508 SILrated and encompasses the followingelements:
• HIPPS Dossier• Pressure transmitters• High integrity manifolds• Logic solvers - programmable or hardwired
• Axial flow and fully piggable ball or gate valves, complete with actuators incorporating partial stroke testing if required
Applications
10
Innovative Black Channel Communications
SELLA CONTROLS’ black channel solutions for remote wellhead,distributed Fire & Gas Detection and Tank Overfill ProtectionSolutions (TOPS), provides reliable and highly cost effectiveprotection for both plant and personnel.
Utilising programmable logic controllers, the system can operateeither as single point to point or on a multiple node networkinstallation. With suitable field instruments and valves it can beused in applications up to and including SIL3.
A PES at each end connects directly to the analogue (4-20mA)or digital (24Vdc / VFC) field I/O.
The PESs then transmit the shutdown signals to each otherusing the Safe Ethernet SIL 3 certified black channelcommunication protocol. As per IEC 61508, the integrity of theblack channel safety is independent of the media due to theproperties and deterministic nature of the protocol, therefore thesignals have a capability of up to SIL3. The only performanceconsiderations are latency (process safety time) andavailability. Availability can be increased through redundant linksor redundant PESs.
www.sellacontrols.com
Fire & Gas Detection (F&G)
SELLA CONTROLS provides equipment from approved thirdparty suppliers and recognised fire and gas detectormanufacturers. Protection devices, CCTV, alarm and HVACcontrol systems can also be supplied.
Our F&G systems are generally programmable in order to caterfor complex alarming arrangements and we use equipmentcertified up to SIL3 in accordance with IEC 61508 that alsooffers line monitoring as standard. Single or dual I/O versionscan be supplied (for increased availability) but even oursimplex I/O solutions are SIL3 capable.
Typically, F&G systems are designed with dual communicationslinks for increased availability and are offered with the followingprotocols: Modbus RTU slave RS485, Ethernet OPC andProfibus DP slave. Giving a wide range of c o n n e c t i o npossibilities with plant control systems.
Addressable
SELLA CONTROLS in parallel to PESbased solutions can also offer addressablesystems for F&G applications using variousmanufacturers.
SCADA/HMI
Over a number of years SELLA CONTROLShave developed SCADA packages fora p p l i c a t i o n s s u c h a s F & G u s i n gproprietary building blocks. Delivering aunique package to clients bespokerequirements, this offers visual indication,visualisation of plant process, statusalarms, annunciation, reporting facilities,remote access, CCTV interface andremote alarms.
11
Fire & Gas detection systems encompass a turnkey solution that includes sensing elements, TÜV certifiedlogic solvers and protection devices.
Panel Build and Design
SELLA CONTROLS works directly with end users, productmanufacturers and engineering houses. Our specialist systemsintegrator experience delivers panel build projects which areinnovative, cost effective and provide the best solution for theproject either as ’build to print’ manufacture or as ‘designand build’.
With a reference list of projects at sites across the globe, wedesign, engineer and manufacture panels which are fullycompliant with the international standards specified by ourclients. Our build capabilities have been approved by end usersfor many years and all control panels are built to comply withcurrent relevant standards. Our quality management system hasbeen certified to BS EN ISO 9001 since 1989.
SELLA CONTROLS provides a complete range build solutionsutilising over 7,500 sq ft of workshop space dedicated tofabrication, production and testing. Our experienced staff arequalified to design, build and deliver panels diverse in size andcomplexity. From the very small basic wall mounted variety to amuch larger multi suite, mounted in large room size containers,and anything in between. Because these often need to fit intoareas on site where space is restricted, our highly skilled teamof technicians and engineers will fabricate them to customdimensions (specified by the client), in a range of standardor specialised materials.
12
For over 45 years, SELLA CONTROLShas been designing andmanufacturing high quality safetyand control panels acrossa number of industry sectorsincluding oil & gas, chemical,steel, power, nuclear and transport.
www.sellacontrols.com
SELLA CONTROLS are also equipped to provide a selection ofhazardous area panels which are suitable for use in areas witha high possibility of flammable, dust or gas. These panels aremanufactured from materials such as Stainless Steel, Cast Iron,Aluminium or Glass Reinforced Polyester.
SELLA CONTROLS has experience in providing panels usingthe following techniques for protection:
• Intrinsically Safe - Exia• Explosion / Flame Proof - Exe Exd or Exn• Purged or Pressurised - Exp
13
SELLA CONTROLSoffers a range of panels and cabinets
• Control Panels - stand alone or fully integrated• Interface Panels• Marshalling Cabinets• Mimics and Mosaics• Pneumatics• Drives and Switch Gear• Demonstration Rigs• Production Runs• Multi Panel (Junction Boxes)• Purge Panels
Control Room Equipment SELLA CONTROLS’ capability to provide high quality controlpanels is complemented by a selection of control roomequipment delivered in conjunction with product partners.
14
A variety of industrialcontrol room featuresare offered:
• Modular Display Cubes (incorporating Digital Mirror Technology)• TFT LCD Systems (Displays for Professional applications)
• Wall management (Control software for Large Screen Systems)• Supervisory Control and Data Acquisition (SCADA)
• Custom built Desks and Consoles• Tile Mosaic and Mimic Displays
www.sellacontrols.com
Management of Legacy and Obsolete Components and Systems
Aftersales
Operator owners are now looking to extend life expectancyof mature plants. Under these conditions, some controls andlogic solvers are becoming obsolete or difficult to maintain,therefore an upgrade or replacement is necessary. Replacingthe existing systems requires good documentation of theexisting systems. With these being in some cases over25 years old, then the records become incomplete or out ofdate.
SELLA CONTROLS has gained knowledge and realisationin implementing reverse engineering activities and site surveysto verify and validate the system documentation. This is inparallel with a mature and tested process to deliver a reverseengineering exercise, using a bespoke dynamic software toolto verify the results.
15
SELLA CONTROLS’ dedicated TechnicalSupport Group provides site installationand commissioning services togetherwith a comprehensive range of postinstallation support and training to fullysupport any system we have installed.SCATS and OPITO certified personnelcan provide technical support for anysystem we supply either onshore oroffshore.
We offer qualified and coordinated servicestailored to individual customer requirementsfor all phases of the safety lifecycle.SELLA CONTROLS can provide yourorganisation with a number of cost-effectivesupport services. Investment in theseservices will provide clear benefits to safetyand maximise process availability.
Sella Controls LtdCarrington Field StreetStockport, CheshireSK1 3JNUnited Kingdom
Tel: +44 (0)161 429 4500Fax: +44 (0)161 476 3095Email: [email protected]
