official emersonprocess ppt presentation template...emerson confidential 27-jun-01, slide 21...
TRANSCRIPT
HIPPS Solution Danish Offshore Show
Esbjerg, March 26th 2015
Carsten Thøgersen
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 2
Agenda
Increased demand for HIPPS, why?
Short about HIPPS and the benefits
The Challenges faced
Challenges on a product level
A Solution addressing all challenges/phases
Questions
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 3
Increased demand for HIPPS, Why?
The increased demand for HIPPS is driven by different factors.
Environmental issues
Regulatory Directives – Reduce Flare
Reduce OPEX (test of relief valves)
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 4
Short about HIPPS and the benefits
Shutting off the source
Protecting Personnel
Automatic Testing
Last line of defence
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 6
The Challenges faced
Consider random as
well as systematic
integrity
Lack of Standards
Monitor and test with
system in service? (Fast
closing)
What if failures are
detected by diagnostic?
Regulations a moving target
IPPC Directives 2008/1/EC
20+20+20 by 2020
Compliance with
current functional
safety legislation for
all elements of the SIF
Handling of multiple
vendors / consultants
Validation of SRS
Defining SRS and
ensure requirements
are followed through
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 7
Challenges Engineering a HIPPS - The causes of failure and the answers
Random failures
Occur due to:
– Inappropriate application
– Bad design
– Fatigue
Reduced by
– Material quality
– Consistent appropriate design
– Performance monitoring
Everything breaks eventually
Systematic failures
Occur due to:
– Designed in
– Engineered in
– Procedural
Reduced by:
– Better processes
– Regular Verification
– Consistent behaviour
People make mistakes
All components of any solution can fail dangerously
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 8
The causes of failure and the answers
Ensure structure and management of all activities
Identify activities and objectives
Manage verification steps
Control the effect of people in every activity
Systematic failures Answer - The safety lifecycle
Random Failures Answer – Safety Integrity Levels
Risk inherent in the process
Tolerable risk region
Other risk
reduction
measures
Risk reduction
by Safety
Instrumented
System
Incre
asin
g r
isk
Residual risk
Measure risk
Quantify instrumented risk reduction target – SIL
Match design to SIL – PFD etc
Monitor performance, adjust design
Control the effect of dangerous failures
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 10
Certified SIS Products and Processes
IEC 61508 Certified Products: – DeltaV SIS, Rosemount, Bettis, Fisher, ASCO and Virgo are IEC 61508 Certified
IEC 61511 Certified Processes: – Global Investment in the development of “SIS Processes”
– All Integration Centers are fully certified to IEC 61511
– Provide a single, worldwide framework for consistent designs
Operation
Implementation
Analysis
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 11
Challenges on a product level - Valve
Closing Speed < 2” regardless of size
Critical on larger diameters / higher ratings
- Inertia
- Repeatability /Reliability
Must not affect tightness
- Linear speed
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 12
Challenges on a product level - Valves
Inertia
Drive train design criticalities
- Torque impulses
- Ball – stem coupling
- Slot vs Spline
- Surface treatments
- Shear keys
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 13
Challenges on a product level - Valves
Repeatability – Life Cycle
- Design criticalities
- Materials
- Overlays
- Bushings
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 14
Challenges on a product level
Tightness reliability
- Actuator parameters
- Over-speed control
- End-stroke dampener
- Seat design
- Seat /Seal materials and mating
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 15
Challenges on a product level - Valves
Design Know How
- Valve Construction
- Trim
- Contact areas
- Automation
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 17
Challenges on a product level
VOS - Valve Operating System
• Diagnostic on Fast Acting ESDV
applications
• High Diagnostic Coverage
• Test of all critical control elements
in the shut down circuit with the
system in Service
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 18
Increased Diagnostic Coverage
Diagnose mechanical failures before
they happen
AMS ValveLink uploads PST results
for analysis
Additional diagnostics
Volume Booster tested as part of
PST
Solenoids testing (50-100mSec)
Friction build-up
Valve shaft shear
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 19
Logic Solver
Simple “HMI”
Status Lamps
Override Keyswitches
Challenges on a product level
Certified with SC3 (SIL3)
Partial Stroke Capability
Comms interface with DCS
HART Pass-through
Smart SISTM Diagnostics
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 20
Challenges on a product level
Logic Solvers can also be
mounted “Locally” on the HIPPS
or
As part of a skid.
Pre-wired, pre-tested, Validated
and with a fiber-Optic connection
back to a Central SCADA system
Zone 2 in a IP54/65 enclosure or
Zone 1 in a EEx d enclosure
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 21
Pressure Sensors Plugged Impulse line (SPM)
Systematic Capability: SC3
Advanced Diagnostics (DA2)
Rosemount 3051S
High Integrity Manifold – 3 tapings
Block-Bleed-Block for test
Single Isolation Key for 3 sensors
ATEX Junction Boxes
Challenges on a product level
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 22
A Solution addressing all challenges
• Certified Systematic Capability3
• The HIPPS Design use Certified
procedures acc. to IEC 61511
• Single Supplier Management
• Verification of SIL
• IEC 61 508 and 511
compliant
• Proof test and Inspection plan
• Calibration and Operation
records
• IOM for HIPPS
• Compliance report to ensure
Safety Lifetime is addressed
• Validation if required
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 23
Questions
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 24
Back up Slides
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 25
S
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Complete HIPPS Solution
PSS – Digital control
• DeltaV – SIS Logic Solver
Rosemount Pressure Sensors
Final Element
Valve Automation
• Actuation – Bettis
• Pneumatic/Hydraulic Controls (Solenoids
etc)
• Fisher DVC - Valve Control for PST and
diagnostic
Valve
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 26
Products photo
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 27
Products photo
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 28
Products photo
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 29
Products photo
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 30
Products photo