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SafetySIL Emergency Shutdown Block Valve System

Date post: 07-May-2015
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An Introduction to the SafetySIL Fault-tolerant, On-line Full-stroke Testing, Emergency Shutdown Block Valve System
34
Revolutionizing the way the Process, Production & Pipeline Industries Deal with Safety Critical Systems Safety Safety SIL SIL
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Page 1: SafetySIL Emergency Shutdown Block Valve System

Revolutionizing the way the Process, Production & Pipeline Industries Deal with

Safety Critical Systems

SafetySafetySILSIL

Page 2: SafetySIL Emergency Shutdown Block Valve System

SafetySafetySILSIL

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

WELCOME

To the World’s First & OnlyOn-Line, Fault-tolerant, Full-Stroke TestingEmergency Shutdown Block Valve System

Page 3: SafetySIL Emergency Shutdown Block Valve System

Revolutionizing the way the Oilfield Industries Deal with Safety Critical Systems

SafetySafetySILSILINTRODUCING: THE SafetySafetySILSIL BLOCK VALVE SYSTEM

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

Page 4: SafetySIL Emergency Shutdown Block Valve System

Revolutionizing the way the Production Industries Deal with Safety Critical Systems

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

SafetySafetySILSIL

Both Valves Open

dP Transmitter at Middle

Normal Mode

Page 5: SafetySIL Emergency Shutdown Block Valve System

Revolutionizing the way the Process Industries Deal with Safety Critical Systems

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

SafetySafetySILSIL

“B” Valve Closed

dP Transmitter drawn downBernoulli Effect Pulls Down Dead Leg

SIL Test – 1st Half Cycle

Page 6: SafetySIL Emergency Shutdown Block Valve System

Revolutionizing the way the Production Industries Deal with Safety Critical Systems

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

SafetySafetySILSIL

Both Valves Open

dP Transmitter at Middle

Transitioning

Page 7: SafetySIL Emergency Shutdown Block Valve System

Revolutionizing the way the Process Industries Deal with Safety Critical Systems

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

SafetySafetySILSIL

“A” Valve Closed

dP Transmitter pulled upBernoulli Effect Pulls Down Dead Leg

SIL Test – 2nd Half Cycle

Page 8: SafetySIL Emergency Shutdown Block Valve System

Revolutionizing the way the Process Industries Deal with Safety Critical Systems

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

SafetySafetySILSIL

Both Valves Open

dP Transmitter at Middle

Return to Normal Mode

Page 9: SafetySIL Emergency Shutdown Block Valve System

SafetySafetySILSIL

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

Applying the SafetySIL

Regulatory OversightOperator’s Risk Strategy

Safety Integrity Level (SIL)

Page 10: SafetySIL Emergency Shutdown Block Valve System

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.”

SafetySafetySILSILFEDERAL & STATE REGULATORY OVERSIGHT

Page 11: SafetySIL Emergency Shutdown Block Valve System

Revolutionizing the way the Process Industries Deal with Safety Critical Systems

SafetySafetySILSILOPERATORS 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)

Page 12: SafetySIL Emergency Shutdown Block Valve System

Revolutionizing the way the Process Industries Deal with Safety Critical Systems

SafetySafetySILSILSAFETY 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

Page 13: SafetySIL Emergency Shutdown Block Valve System

Revolutionizing the way the Process Industries Deal with Safety Critical Systems

SafetySafetySILSILINCREASING 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

Page 14: SafetySIL Emergency Shutdown Block Valve System

Revolutionizing the way the Process Industries Deal with Safety Critical Systems

SafetySafetySILSIL

SIL = Testing Frequency

(PFD X Demand Rate)

SIL RELATIONSHIP DEFINED

TESTING FREQUENCY ↑ = SIL ↑

PDF ↓ = SIL ↑

DEMAND RATE ↓ = SIL ↑

Page 15: SafetySIL Emergency Shutdown Block Valve System

Revolutionizing the way the Process Industries Deal with Safety Critical Systems

SafetySafetySILSILFREQUENCY 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

Page 16: SafetySIL Emergency Shutdown Block Valve System

Revolutionizing the way the Process Industries Deal with Safety Critical Systems

SafetySafetySILSILSIL 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 0.0001% 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)

Page 17: SafetySIL Emergency Shutdown Block Valve System

Revolutionizing the way the Process Industries Deal with Safety Critical Systems

SafetySafetySILSIL

CONTRIBUTIONS TO SIS FAILURES OF THEFINAL 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)

Page 18: SafetySIL Emergency Shutdown Block Valve System

Revolutionizing the way the Process Industries Deal with Safety Critical Systems

SafetySafetySILSIL

Page 19: SafetySIL Emergency Shutdown Block Valve System

Revolutionizing the way the Process Industries Deal with Safety Critical Systems

SafetySafetySILSILSIS 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

Page 20: SafetySIL Emergency Shutdown Block Valve System

Revolutionizing the way the Process Industries Deal with Safety Critical Systems

SafetySafetySILSILSIS 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)

Page 21: SafetySIL Emergency Shutdown Block Valve System

Revolutionizing the way the Process Industries Deal with Safety Critical Systems

SafetySafetySILSILSIS 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)

Page 22: SafetySIL Emergency Shutdown Block Valve System

Revolutionizing the way the Process Industries Deal with Safety Critical Systems

SafetySafetySILSILSIS 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%?

Page 23: SafetySIL Emergency Shutdown Block Valve System

Revolutionizing the way the Process Industries Deal with Safety Critical Systems

SafetySafetySILSILSIS BLOCK VALVE TESTING

Page 24: SafetySIL Emergency Shutdown Block Valve System

Revolutionizing the way the Process Industries Deal with Safety Critical Systems

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

opinion of Partial Stoke Technology!

Page 25: SafetySIL Emergency Shutdown Block Valve System

Revolutionizing the way the Process Industries Deal with Safety Critical Systems

SafetySafetySILSILSIS BLOCK VALVE TESTING

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!!!

Page 26: SafetySIL Emergency Shutdown Block Valve System

Revolutionizing the way the Process Industries Deal with Safety Critical Systems

SafetySafetySILSIL

Page 27: SafetySIL Emergency Shutdown Block Valve System

Revolutionizing the way the Process Industries Deal with Safety Critical Systems

THE SafetySafetySILSIL WHY’S:

SafetySafetySILSIL

Page 28: SafetySIL Emergency Shutdown Block Valve System

Revolutionizing the way the Process Industries Deal with Safety Critical Systems

SafetySafetySILSILTHE SafetySafetySILSIL WHY’S

WHY DOES THE SafetySafetySILSIL 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!!!

Page 29: SafetySIL Emergency Shutdown Block Valve System

Revolutionizing the way the Process Industries Deal with Safety Critical Systems

SafetySafetySILSILTHE SafetySafetySILSIL WHY’S

WHY DOES THE SafetySafetySILSIL 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

Page 30: SafetySIL Emergency Shutdown Block Valve System

Revolutionizing the way the Process Industries Deal with Safety Critical Systems

SafetySafetySILSILTHE SafetySafetySILSIL WHY’S

WHY DOES THE SafetySafetySILSIL 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!

Page 31: SafetySIL Emergency Shutdown Block Valve System

Revolutionizing the way the Process Industries Deal with Safety Critical Systems

SafetySafetySILSILTHE SafetySafetySILSIL WHY’S

WHY DOES THE SafetySafetySILSIL 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!

Page 32: SafetySIL Emergency Shutdown Block Valve System

Revolutionizing the way the Process Industries Deal with Safety Critical Systems

SafetySafetySILSILTHE SafetySafetySILSIL WHY’S

WHY DOES THE SafetySafetySILSIL 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 SafetySafetySILSIL FUNCTION CAN PROVIDE SIL-4

• ELIMINATES NEED FOR MULTIPLE SIL-1 LAYERS OF PROTECTION

• CAN USE LESS EXPENSIVE VALVES AND OTHER EQUIPMENT (LOWER MTBFS)

Page 33: SafetySIL Emergency Shutdown Block Valve System

Revolutionizing the way the Process Industries Deal with Safety Critical Systems

SafetySafetySILSIL

THE ONLY:

ON-LINE

FULL STROKE TESTING

FAULT TOLERANT

SIL CAPABLE

BLOCK VALVE SYSTEM

THE REVOLUTION IN FAULT TOLERANT TECHNOLOGY!

Page 34: SafetySIL Emergency Shutdown Block Valve System

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

SafetySafetySILSILSafetySIL, LLC’s PARTNER

IN PRODUCTION, FACTORY ACCEPTANCE TESTING ANDFIELD SUPPORT FOR

• INSTALLATION,• CONFIGURATION• MAINTENANCE• TRAINING


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