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SafetySIL Emergency Shutdown Valve System Introductory Presentation

Date post: 07-Jun-2015
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Presenting the SafetySIL Fault-tolerant, On-Line Full-stroke Testing Emergency Shutdown Block Valve System
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Revolutionizing the way the Process, Production & Pipeline Industries Deal with Safety Critical Systems SafetySIL
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  • 1. Revolutionizing the way the Process, Production & Pipeline Industries Deal with Safety Critical Systems SafetySIL

2. SafetySIL Revolutionizing the way the Oil Field Industries Deal with Safety Critical Systems WELCOME To the Worlds First & Only On-Line, Fault-tolerant, Full-Stroke Testing Emergency Shutdown Block Valve System 3. 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 4. Revolutionizing the way the Oilfield Industries Deal with Safety Critical Systems SafetySIL 5. SafetySIL Revolutionizing the way the Oil Field Industries Deal with Safety Critical Systems Applying the SafetySIL Regulatory Oversight Operators Risk Strategy Safety Integrity Level (SIL) 6. 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 7. Revolutionizing the way the Process Industries Deal with Safety Critical Systems 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) 8. Revolutionizing the way the Process Industries Deal with Safety Critical Systems 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 9. Revolutionizing the way the Process Industries Deal with Safety Critical Systems 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 10. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySIL SIL = Testing Frequency (PFD X Demand Rate) SIL RELATIONSHIP DEFINED TESTING FREQUENCY = SIL PDF = SIL DEMAND RATE = SIL 11. Revolutionizing the way the Process Industries Deal with Safety Critical Systems 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 12. Revolutionizing the way the Process Industries Deal with Safety Critical Systems 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) 13. Revolutionizing the way the Process Industries Deal with Safety Critical Systems 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) 14. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySIL 15. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySIL SIS SYSTEM DESIGN WHEN DESIGNING A SIS: USE EQUIPMENT WITH A LARGE MTBF (DOESNT 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 16. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySIL SIS BLOCK VALVE DESIGN TWO (2) BLOCK VALVES IN SERIES: INCREASE SAFETY WITHOUT THE NEED TO TEST MORE FREQUENTLY UNLIKELY THAT BOTH VALVES 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) 17. Revolutionizing the way the Process Industries Deal with Safety Critical Systems 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) 18. Revolutionizing the way the Process Industries Deal with Safety Critical Systems 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%? 19. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySIL SIS BLOCK VALVE TESTING 20. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySIL This screen print from a large, international partial stroke testing manufacturer shows their opinion of Partial Stoke Technology! 21. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySIL SIS 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!!! 22. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySIL 23. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySIL 24. Revolutionizing the way the Process Industries Deal with Safety Critical Systems THE SafetySIL WHYS: SafetySIL 25. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySIL THE SafetySIL WHYS 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!!! 26. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySIL THE SafetySIL WHYS 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 27. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySIL THE SafetySIL WHYS 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! 28. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySIL THE SafetySIL WHYS 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 VALVES ARE FUNCTIONING AS EXPECTED REDUCTION IN MAINTENANCE COSTS ARE PURE PROFIT! 29. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySIL THE SafetySIL WHYS 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) 30. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySIL THE ONLY: ON-LINE FULL STROKE TESTING FAULT TOLERANT SIL CAPABLE BLOCK VALVE SYSTEM THE REVOLUTION IN FAULT TOLERANT TECHNOLOGY! 31. Revolutionizing the way the Process, Oilfield & Pipeline Industries Deal with Safety Critical Systems SafetySIL SafetySIL, LLCs PARTNER IN PRODUCTION, FACTORY ACCEPTANCE TESTING AND FIELD SUPPORT FOR INSTALLATION, CONFIGURATION MAINTENANCE TRAINING


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