Integration of Safety Lifecycle Tools and PLC Programming

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Integration of Safety Lifecycle Tools and PLC
Programming

• Iwan van Beurden, exida
• Charlie Fialkowski, Siemens

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Presenters Co-authors

• exida
• Iwan van Beurden, MSc, CFSE
• Senior Safety Engineer
• exSILentia product Manager
• Siemens
• Charlie Fialkowski, CFSE
• Safety System Product Manager
• John Cusimano, CFSE
• Business Development Manager, Process Safety
  Systems
• Patricia Ela

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Integration of Safety Lifecycle Tools and PLC
Programming

• Safety Lifecycle Phases
• Example HIPPS
• Safety Lifecycle Engineering Tools
• SIL Selection
• SIL Verification (conceptual design)
• Cause Effect Matrix (detailed design)
• Integration of exSILentia and Safety Matrix

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ANSI/ISA 84.00.01-2004 Safety Lifecycle
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Example HIPPS Safety Instrumented Function

• Example Process
• Heat used to separate petroleum into various
  components in distillation column
• Hazard identified
• Column C-51 Overpressure, with Possible
  Overloading of Flare System
• Safety Instrumented Function
• High Pressure on Column C-51 Causes Steam Supply
  to Reboiler E-52 to Close

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SIL Selection

• Assume
• Demand frequency
• Over pressure every 3 years
• Consequence
• Single Fatality
• Economic Loss of 4 Million

SIF Item Hazard Description Inputs Outputs Target SIL
SIF 1 Column C-51 overpressure, with possible overloading of flare system. High Pressure on Column C-51 causes Steam Supply to Reboiler E-52 to close. PT-51PT-52PT-53(2oo3) XV-51 CloseXV-52 Close(1oo2) 3
Note Target SIL and input / output voting are
for illustrative examples only and are not to be
taken as typical, suggested or recommended.
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Conceptual Design (I)
PT-51
2oo3
1oo2
PT-52
Logic Solver
PT-53
XV-51
XV-52
SIF Item Hazard Description Inputs Outputs Target SIL
SIF 1 Column C-51 overpressure, with possible overloading of flare system. High Pressure on Column C-51 causes Steam Supply to Reboiler E-52 to close. PT-51PT-52PT-53(2oo3) XV-51 CloseXV-52 Close(1oo2) 3
Note Target SIL and input / output voting are
for illustrative examples only and are not to be
taken as typical, suggested or recommended.
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Conceptual Design (II)
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Detailed Design
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exSILentia to Safety Matrix Integration Workflow
project.exi exSILentia export file
exSILentia to Safety Matrix Utility
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SIMATIC Safety Matrix for HIPPS Example
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The Safety Lifecycle - Objectives

• Build safer systems that do not experience as
  many of the problems of the past
• Build more cost effective systems that match
  design with risk
• Eliminate weak link designs that cost much but
  provide little
• Provide a global framework for consistent designs

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Summary

• The ANSI/ISA 84.00.01-2004 (IEC 61511 Mod.)
  offers the opportunity to design safer systems
  and optimize cost
• Safety Lifecycle implementation can be
  engineering and documentation intensive
• Various software tools address different phases
  of the Safety Lifecycle
• exSILentia covers SIL selection, SIL verification
  and reliability calculations
• SIMATIC Safety Matrix is a Cause and Effect
  Matrix design, programming, and operations and
  maintenance tool
• Import utility provides a comprehensive cost
  effect and less error prone solution for managing
  the entire Safety Lifecycle

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Path Forward

• Standardize a conceptual design to detailed
  design transition format

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Integration of Safety Lifecycle Tools and PLC
Programming

• Iwan van Beurden, exida
• Charlie Fialkowski, Siemens