The total solution for a HIPPS requirement

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The total solution fora HIPPS requirement
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ir. Hein C. SteinzSales Marketing Solid
Safety Solutions

• Graduated master degree electronics 1978
• Started safety systems development Holec 1983
• Yokogawa since 1997, commercial since 2001
• Born 1951, married, two kids, a boy and a girl
• Hobbys

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Introduction

• Nowadays it is obvious that solving the HIPPS
  requirement or any other safety challenge is a
  matter of observing the total loop from process
  variable to process variable.
• It is, since a long time now, not a matter
  anymore of individual components or suppliers.

A chain is only as strong
as the weakest link

• Or, like the picture, the HIPPS chain is only as
  strong as the weakest link.

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Contents

• HIPPS, an overall loop requirement
• Manifolds
• Transmitters
• Logic Solver
• Solenoids and HIPPS Valves
• Partial stroke testing
• Communication and sequence of event registration
• Plant Resource Manager

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Typical HIPPS solution
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Important specifications

• Safety Integrity Level (SIL),
• Process Safety Time,

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Requirements

• General description of the process to be
  protected.
• General description of how HIPPS is integrated
  into the process and other safety systems,
  including the objectives of what the HIPPS shall
  protect, and how and when it is activated.
• The required SIL level of the loop and the
  minimum acceptable initial loop average
  Probability of Failure on Demand (Pfd average).
• The required minimum proof test interval and a
  description on how the operator proposes to proof
  test the HIPPS. This is directly related to the
  production availability and therefore an
  important issue in the specifications.
• Specification of the system response time and the
  criticality thereof in relation to the time
  before over-pressure occurs.
• Detailed specification of the final element
  (shut-off valve) describing materials, design
  standards, actuator sizing/integration, details
  of the instrumentation such as solenoids and
  actuator. Specific safety aspects shall be
  addressed. Reference to a design standard like
  DIN 3381 can be considered.
• Detailed specification of the pressure
  transmitters and their safety aspects.
• Detailed specification of the controller
  including the required logging, local readout,
  test buttons, and communication to other
  controllers like the DCS. Event recorders shall
  be considered, also to record proof-tests.
• Components tests and integrated factory
  acceptance test (FAT) requirements for the
  complete system.
• Documentation requirements that may include
  procedures and checklists for the site acceptance
  test (SAT) and proof testing of the system.

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Manifolds

• Manifolds for the transmitters have to provide
  the necessary double block and bleed interlocking
  2oo3 arrangement especially for HIPPS.
• Special attention has to be paid on the
  specifications and functionality of the manifolds
  to use.
• measures against clogging such as
• size of the process connection,
• mounting instructions
• temperature monitoring
• heating,
• Double block and bleed on (most of the time)
  three transmitters with mechanical interlocking
  on the transmitter selection, limit switches to
  monitor the position of the mechanical
  interlocking and the capability of applying a
  test pressure to individual transmitters.

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Transmitters

• Pressure Measurement Component in Safety
  Instrumented Systems.
• To meet at least all requirements for a single
  instrument in SIL2 loop or two transmitters in
  SIL3 Loop.

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Logic solver

• Highest safety class available
• TÜV AK 1 7 / SIL 4 certification
• Inherently Fail-Safe
• Zone 2 applications
• Very high mechanical and electrical robustness
• High temperature range
• Very low power consumption
• Physical/Galvanic separations
• Very high EMC immunity
• Very long technical life span (gt 30y)
• Test intervals many years
• Low Cost of Ownership
• Event Recorder (1 ms resolution)

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Actuators and valves

• Large valves
• Very fast closing time.
• Single component will not satisfy the safety
  requirements and there will be a need for
  configurations is series and parallel for safety
  but also for availability.

• Specifically designed for fast reliable stroking
  over an extended service life.
• On failure, they are to close the final element.

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Partial stroke testing

• Every test done on a HIPPS will have to prove at
  least two things
• its capability to close and
• within the specified time.
• Partial stroke testing can give you an indication
  and might remove some faults from the Pfd list
  to the known failure modes, but too often
  partial stroking will result in a vast data flow,
  which is to be stored and evaluated and, for
  higher SIL and fast acting applications, it
  cannot replace a real proof test.

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Communication / sequence of event recording

• Part of total instrumentation jobs
• Need for communication
• Existence of a firewall around the logic solver
• Event registration is very useful, when
  synchronized with other process related systems,
  to determine what actual happened.
• Show the timed response
• Timing is the keyword
• Proper documented, can be used as
• a proof test

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Plant Resource Manager

• PRM or Asset Management is a dynamic software
  tool that supports the daily business activities
  of maintenance personnel.
• The Plant Resource Manager Package for the
  digital network era of fieldbus efficiently
  handles field device management and maintenance
  work for the FOUNDATION fieldbus and HART
  devices, which helps reduce Total Cost of
  Ownership in the plant.
• Incorporating the transmitters and, if present
  for example for partial stroke testing or valve
  signatures, valve positioners will be a valuable
  add on the HIPPS functionality and especially
  maintainability.
• Advanced diagnostics on the transmitters and
  valves might reduce the necessary test intervals,
  however at least once per year is still
  recommended.

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Conclusion

• Dont go shopping for bargains when you want to
  realize a HIPPS solution.
• Go for the balanced solution for both functional
  and safety requirements.
• Be sure there is sole responsibility for your
  total loop and be sure this is a competent person
  or company.

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Thank you for your attention.
Commitment means building the future to last.