20
Process Safety Symposium 2019
Safety in pneumatic control
About SIL and how to read certificates 1
Market requirement and solution 2
Use cases for safety circuits 3
Market requirement and solution 2
Use cases for safety circuits 3
Safety in pneumatic control
About SIL and how to read certificates 1
What is functional safety
Basic Standard belong to functional safety
IEC 61508 Basic for Spezification, Design and Operation of safety related Systems
electric/electronic/programmable electronic Systems E/E/PES
IEC 61511 Application specific standard
Safety related system SIS
Process- Industry
ISO 13849 For safety refered components
of a control
(follow up Machine guidline DIN 954) SRP/CS
IEC 62061 safefty of machinery
safety related electrical control system SRECS
Machine building - Industry
What is functional safety
Risk estimation with risk graph SIL
SIL safety – integrity level
The plant engineers determine in cooperation with the authorities the risk and thus the safety Integrity level for the safety systems
A safety-instrumented-system (SIS) consists of
sensor,
control/signal processing and actuator
The plant engineer builds the safety-integrated-
system
to perform the safety function
control sensor actuato
r
What is functional safety
DEVIATION CAUSE CONSEQUENCE SAFEGUARDS ACTION
Temperature transmitter alarm: max. allowed Temperature reached
Steam Control valve V5 doesn`t work correctly (close)
Reactor over heating Cooling water (V4) opens Automatic closure of valve V1; V2 and V5
M
M
M
Cooling water
Steam
Fluid A
Fluid B
Evolution of certificates – how to read them
How to read and common missunderstandings. Old but still available certificates:
New style of certificates:
Certificates only show the suitability of the individual component in a safety circuit. The required architecture is often not apparent at first glance.
Evolution of certificates – Safety manual
About SIL and how to read certificates 1
Use cases for safety circuits 3
Market requirement and solution 2
Market needs and solution
Market needs and solution
Background of Limitation in certificates
O-Rings and grease as critical parts in respect of life time and wearing - Means higher failure rate compared with designs without dynamic seals
Market needs and solution
Do we find other solutions in field?
• In 2002, Bayer invested around €110 million in the construction of a multi-purpose • system at its site in Dormagen, Germany. This houses everything under a single roof, • from the development and manufacture of new active ingredients for crop protection, • as well as laboratory processing, sampling and piloting, right up to the production
processes.
• The ability to use Festo solenoid valves universally and their adherence to strict safety • requirements were all convincing arguments for the decision makers at Bayer. More
than • 1,500 solenoid valves VOFC were installed in safety-related as well as non-safety-
related • circuits in the multi-purpose system. A large number of these valves is used to actuate
ball • valve units at tank systems, reactors, media supply systems and other applications.
• And the solenoid valves still running without any failure!!!
Market needs and solution
The solution for extended life time
VOFC – Solenoid valve without dynamic seals and long term expirience in field
Test Result:
there was no mailfunction of the safety function (closed position) during all test cycles
Sum of switching cycles for 20 valves
Failure
Test LDM 8.980 0
Test HDM 30.000.000 0
SUM 30.008.980 0
Cycles each valve PFD
1.500.449 2*10-6
Market needs and solution
SIL Certificate.
Market needs and solution
HFT (Hardware Failure Tolerance).
1oo2 – Block redundant safety
Both blocks look the same externally, but the ports are internally linked differently.
Both variants can be used as NAMUR- or Inline-block.
2oo2 – Block redundant availability
Market requirement and solution 2
Use cases for safety circuits 3
About SIL and how to read certificates 1
Solutions for batch processes.
Valve terminal with integrated safety shutdown to control separate actuators.
Operating mode of in series connected devices via fieldbus and valve terminal.
Safety mode via safety PLC and valve terminal.
Solution for SIL 2 loops.
With redundant linking, SIL levels can be increased.
Solutions for batch processes.
Valve terminal with integrated safety shutdown to control actuators for operating and safety mode.
Operating mode via fieldbus and valve terminal.
For safety mode, separate supply for safety shutdown of the pneumatically actuated check valves.
Solution for SIL 2 loops.
With redundant linking, SIL levels can be increased.
Solutions for batch processes.
Valve terminal plus single solenoid valve for safety shutdown.
Operating mode via valve terminal.
Safety mode via SIL certified single solenoid valve mounted on the actuator.
Solenoid valves can be used up to SIL 3.
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