A Case Study: SAFETY INSTRUMENTED BURNER MANAGEMENT SYSTEM SIBMS

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A Case Study SAFETY INSTRUMENTED BURNER
MANAGEMENT SYSTEM (SI-BMS)

• Safety Symposium
• Houston, TX
• May 24, 2006

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Mike Scott, PE, CFSE

• VP, Process Safety with AE Solutions
• Registered Professional Engineer in AK, SC,GA
  IL
• Certified Functional Safety Expert (CFSE)
• Author / presenter of numerous technical papers
  on process safety
• ISA Instructor
• SI-BMS Webinar
• SI-FGS Webinar
• SI-BMS Class
• ISA SP84 Committee Member
• BMS Subcommittee member
• FGS Subcommittee co-chair
• ISA Safety Division BMS sub-committee chair

 
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Bud Adler

• Director, Business Development with AE Solutions
• Active in process instrumentation field for over
  40 years
• Numerous sales, marketing and executive positions
  with instrumentation vendors
• Life Member of ISA
• Member of ISA SP84 Safety Committee
• Member of the BMS Subcommittee
• Member of the FGS Subcommittee
• Author of numerous technical papers related to
  process safety
• Frequent presenter at technical conferences and
  user seminars worldwide
• Director-elect of ISA Safety Division

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Project Overview

• Installation of two (2) new redundant Boilers
• Single Burner Boiler (NFPA 85)
• Capable of firing natural gas, oil and / or waste
  gas
• 1365 PSIG steam at 310,000 lbs/hr
• Client is fully S84 aware and has implemented
  numerous IEC61511 compliant projects
• Complex multiple entity project team

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Project Team Organization Chart

• Multiple sub-contractors
• Various degrees of SIS application knowledge
• Boiler OEM had primary PO for Boiler
• Burner OEM and SI-BMS contracts were subs to
  Boiler OEM

SIS Aware
Semi-SIS Aware
NON-SIS Aware
NON-SIS Aware
SIS Aware
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Construction Industry Institute

• Front End Loading effort level directly affects
  the cost and schedule predictability of the
  project.
• As the level of FEL tasks increase
• The project cost performance from authorization
  decreases by as much as 20
• The variance between project schedule performance
  versus authorization decreases by as much as 39
• The plant design capacity attained and facility
  utilization improved by as 15
• The project scope changes after authorization
  tend to decrease
• The likelihood that a project met or exceeded its
  financial goals increased

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SIS FEL Package

• HAZARD Identification
• Conduct HAZOP
• Risk Assessment
• Perform LOPA
• Develop
• SIF List
• SIS Design Basis Support Report
• Safety Requirements Specification
• Develop
• Lifecycle Cost Analysis
• Interlock List
• Sequence of Operations
• Conceptual Design Specification
• Redline PIDs
• Develop
• System Architecture Diagram
• E-stop Philosophy
• SIS Logic Solver Specification Bill of
  Materials
• Approved Inst Vendor List / Procure Plan for SIS

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Safety Lifecycle
Start
Establish Operating Maintenance Procedures
Project Design Basis / Company Standards
Define Target SIL
Develop Safety Requirements Specification
Conceptual Process Design
Pre-Startup Safety Review Assessment
SIS Startup, Operation, Maintenance, Periodic
Functional Testing
SIS Conceptual Design, Verify Compliance With
SRS
Define PHA Input /Output Requirements
Modify or Decommission SIS?
Perform SIS Detail Design
Perform Process Hazards Analysis Risk Assessment
SIS Installation, Commissioning, and Pre-Startup
Acceptance Test
Apply non-SIS Protection Layers to Prevent
Identified Hazards or Reduce Risks
SIS Decommissioning
Yes
No
SIS Required?
(Based on ISA-S84)
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Initial Design PID NG Bio Gas
SV 110  
FO  
SV 109
SV 108  
Combustion Chamber
Pilot Line
FC  
FC  
SV 105  
Flame Sensor
Igniter
FO  
Main Flame
HV 104
HV 103
BN 102
BS 102A
Natural Gas
Main Flame
BS 102B
Main Gas Line
FC  
FC  
Main Flame
BS 102C
Pilot Flame
SV 105  
BS 102C
FO  
HV 103
HV 104
Bio Gas
Bio Gas Line
FC  
FC  
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Initial Design PID - Oil
Combustion Chamber
HV 204
HV 203
No.2 Oil
Main Oil Line
FC  
FC  
SV 305  
FO  
HV 304
Steam
Atom Steam Line
FC  
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Initial Design PID - Air
ID Fan
STACK
Combustion Chamber
Clean Air
PT 602A
PT 601B
PT 601C
FD Fan
FGR Air
Combustion Air
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Initial Design PID - Steam
Steam Drum
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Economic Safety Analysis
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Risk Analysis Results
7 SIL 1 4 SIL 2 4 - SIL A 1 - MPF
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Is a BMS a SIS?

• Yes, a BMS is a SIS if
• Risk Analysis determines additional risk
  reduction is required and a Safety Integrity
  Level of 1 or greater is assigned to a BMS Safety
  Instrumented Function
• No, a BMS is not a SIS if
• Risk Analysis determines no additional risk
  reduction is required

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SIL Verification Results
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SIL Verification Results
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Economic Safety Analysis
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Benefit-to-Cost-Ratio

•   B-C Ratio FNo-SIS x EVNo-SIS -
  FSIS x EVSIS
• CostSIS
  CostNT
•  
• B-C Ratio Ratio of benefits to cost
• FNo-SIS Frequency of the unwanted event
  without a SIS
• FSIS Frequency of the
  unwanted event with a SIS
• EVNo-SIS Total expected value of loss of
  the event without a SIS
• EVSIS Total expected value of loss
  of the event with a SIS
• CostSIS Total lifecycle cost of the
  SIS (Annualized)
• CostNT Cost incurred due to nuisance
  trips (Annualized)

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B-C Ratio 2oo3 Architectures
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B-C Ratio 1oo1 Architectures
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Economic Safety Analysis
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Lifecycle Cost Analysis
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LCC Analysis Results
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LCC Analysis Results
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Final Results
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Conclusion

• Complex project team with multi-layered
  contractual arrangement
• Implementation of a SIS FEL saved project team
  cost and schedule
• Implementation of Safety Lifecycle reduced Risk
  associated with BMS
• Implementation of Economic Analysis coupled with
  Safety Availability requirements resulted in over
  500K in savings

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Make your money
Conclusion
Proper Implementation of the Safety Lifecycle Can
Reduce Cost of Ownership!
work for you!
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Thank You! Are There Any
Questions
Applied Engineering Solutions, Inc.
www.aesolns.com