Date post: | 07-May-2015 |
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Engineering |
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Revolutionizing the way the Process, Production & Pipeline Industries Deal with
Safety Critical Systems
SafetySafetySILSIL
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
Revolutionizing the way the Oilfield Industries Deal with Safety Critical Systems
SafetySafetySILSILINTRODUCING: THE SafetySafetySILSIL BLOCK VALVE SYSTEM
U. S. Patent No. 6,058,956
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
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
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
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
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
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)
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
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)
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
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
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 ↑
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
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)
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)
Revolutionizing the way the Process Industries Deal with Safety Critical Systems
SafetySafetySILSIL
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
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)
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)
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%?
Revolutionizing the way the Process Industries Deal with Safety Critical Systems
SafetySafetySILSILSIS BLOCK VALVE TESTING
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!
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!!!
Revolutionizing the way the Process Industries Deal with Safety Critical Systems
SafetySafetySILSIL
Revolutionizing the way the Process Industries Deal with Safety Critical Systems
THE SafetySafetySILSIL WHY’S:
SafetySafetySILSIL
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!!!
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
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!
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!
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)
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!
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