roxel solutions presentasjon teknologidag 2014
DESCRIPTION
TRANSCRIPT
Teknologidag – 5 Juni 2014
New regulations for offshore rigs
Jan Forsell – Roxel Solutions AS
My background:
Siemens O&G:- Responsible for F-systems, offshore- Eng manager, Eldfisk SAS upgrade- Eng manager, Statfjord Safety Systems
F&G, ESD, HIPPS, IOPS, OPPS- Project manager, Safety systems
Roxel Solutions AS:- General manager
Jan Forsell – Roxel Solutions AS
Agenda:
• A minute about Roxel
• Short introduction to norms, standards and NPD rules
• SIL in Control System Projects – How to approach?– Rules and regulations– Project execution and verification– Programming tools– Equipment
Roxel Group
• Revenue: 240 MNOK • Resources: 140• 13.400 m2
Supplier of onshore and offshore solutions
LANDBASERT
Drilling equipment packages
Independent system integration of 3’rd party suppliers
Product line:
• Drilling and utility systems• Cabins and LER• Instrumentation• EX equipment• Drives
Mud & Cement – Integrated Solutions
MUD HANDLING SYSTEM
COMPLETE MUD & CEMENT SYSTEM
References PSD EXPRO – Well Testing:
– 6 PSD SIL2 systems delivered– NORSOK – IEC61508/511/OLF070 – DNV– EX zone 1
Halliburton – Well Testing:– 1 PSD system, Under Balanced Drilling– 2 PSD systems, Well Testing
New PSD system presentation Challenges:
High risk potentialHarsh environment Critical processPortable equipment
SAFETY SYSTEMS - Offshore
Safety Systems - OffshoreSafetyIntegrityLevel
SIL4: Not used offshore (Nuclear power plants, train signalling systems)SIL3: Emergency/Critical systems (ESD/HIPPS)SIL2: Process and protection systems (PSD/F&G)SIL1: Lowest level, not used offshore
Safety Instrumented Systems (SIS)
SafetyIntegrityLevel
SIL4: Not used offshore (Nuclear power plants, train signalling systems)SIL3: Emergency/Critical systems (ESD/HIPPS)SIL2: Process and protection systems (PSD/F&G)SIL1: Lowest level, not used offshore
Safety Integrity Levels:
Focus on the complete system (Equipment Under Control)Mandatory risk evaluations – must be documented (SRS)Supplier must document that SIL is obtained
Focus on the complete lifecycle:
Design-Specification-Engineering-Testing-Operation-Demolition
Standards for implementation offshore:
Ptil, Styringsforskrift §5 barriersPtil, Innretningsforskriften §8 safety functions
IEC61508 – Functional safety of control systems, framework, definition of SILIEC61511 – Engineering of safety systems for Process systemsOLF070 – NPD Guideline for minimum SIL levels on the NCS: - Define SIL levels, guidance on how to implement NPD demands
API RP 14C – Risk analysis, failure-mode-effects analysis (FMEA) and hazard-and-operability studies (HAZOPS), define risk levels and barriers, safe charts.
OLF070 specifies API RP 14C / ISO10418 (guideline for analysis, design, installation and testing of process safety systems)
Connections between IEC norms:
Standards for implementation for rigs:
DNV-OS-A101 – Safety Principles and Arrangements
Basic requirments for DNV verification, shutdown logic and alarms.
Standards for implementation rigs:
DNV-OS-D202 – General requirements for safety and control systems: Design, fabrication, installation, testing, commissioning, operation, mainenance, re-qualification, and abandonment.
Availability class (R0) redundancy
Documentation,Ch3.1 Table B2
NORSOKThe D series: Ongoing updates after Macondo incident:
D-002: Well Intervention, BOP SIL demand (also for well intervention)D-007: Well testing, mandatory SIL2 demand after july 2017
NORSOK points to OLF070 for minimum level.
What must be adressed in a SIL project?
BeforeStartDuringAfter
- Government requirements- Customer demands- Internal requirement- Certifying body (DNV/ABS/…)
How to implement:- How to interpret Rules & Regulations- Failure Mode Effect Analysis (FMEA)- Hazard and operability studies (HAZOP)
- Documentation for SIL:Functional Design Specification (FS/FDS)Safety Requirement Specification (SRS)Safe Charts with Cause & EffectSIL loop definition
What must be adressed in a SIL project?
BeforeStartDuringAfter
Interface Meeting:- How to interpret Rules & Regulations- How to document that SIL level is achieved- Responsibility interfaces
Technical (Instrumentation and loops)Formal meetingsContact with certifying body
What must be adressed in a SIL project?
BeforeStartDuringAfter
Personnel qualification:
- Key personnel must be qualified and trained:- Project management- Lead engineers
What must be adressed in a SIL project?
BeforeStartDuringAfter
Ensure that SIL is achieved:
- Project quality control- Documented traceability- Testing and verification- Documented conformity
What must be adressed in a SIL project?
BeforeStartDuringAfter
Project quality control according to ISO9001:
• QA Plan with QA Activity List:- Technical Reviews (FDS/SW/HW/HMI)- Validation according to IAT/FAT procedures
• Safety Assessment and Validation Plan (SA&VP)- Identify and manage all safety aspects - How to verify and test (Nordtest Checklists)- How to implement IEC61508/511/OLF070- Change management (Risk&Impact analysis)
• Node Book:- All required design documents and reports
What must be adressed in a SIL project?
BeforeStartDuringAfter
Installation and Commissioning:
• Procedures for - Storage and transportation- Installation - Commissioning - Testing
• Training:- Operator and Maintenance personnel
What must be adressed in a SIL project?
BeforeStartDuringAfter
After delivery:
• SIL level must be maintained throughout the system lifetime:
- Documentation- Test intervals (instruments and control system)- Modifications and reconfiguration- Repair
Roxel is approved as Solution Integrator by Siemens:
International program:1300 partners world wide7 partners in Norway
Roxel is approved for the following areas:
Process Control System SIMATIC PCS7, specializing on PCS 7 Safety Human Machine Interface SIMATIC HMI Automation System SIMATIC
How the program works:
Support network- Siemens IADT in Oslo- Product experts in Germany
Competence through mandatory training- SIL courses in Germany (3 x 2 weeks)- Work shops- Partner Summits- Information on new products- Demo busses
Siemens Safety Integrated
Why Siemens:
• Most common standard for O&G
• Largest portefolio of IEC61508 equipment
• Reliable and well proven
• Simatic expertise within Roxel
Siemens Safety Integrated Safety according to IEC 61508/61511:
– Programming based on Siemens F-Tools:- Part of Simatic PCS 7 tools- Tested by TÜV
– Equipment based on SIMATIC Safety Integrated Systems (SIS):- S7-315F, single Fail-safe SIL2/3- ET200iSP combine SIL and Ex- F-SM I/O modules «Yellow series»
– Equipment based on SIMATIC PCS7:- S7-400F, single Fail-safe SIL2/3- Safety Matrix- ET200iSP combine SIL and Ex- F-SM I/O modules «Yellow series» Communication:- ProfiSAFE Single communication for Zone 1
Design review by 3rd party (Sintef, DnV, Scanpower…)
Small systems
S7-300F:
• CPU: S7-315F mid-range SIL 3 w/ProfiSAFE DP• Integrated F-SM i/o-cards AI/DI/DO• Redundant power
Benefits:
+ Cheap hardware+ F-SM in one box AI/DI/DO+ Based on F-Library IEC1311 by TÜV+ Good for Small systems with low degree of changes
PCS 7 systems
Technology:– Siemens S7-400 PLC
Software:– Siemens PCS 7– Safety Matrix
Benefits:+ Simplified programming+ More configuring+ Simplified documentation+ Close integration between logic and HMI+ Single or redundant+ Powerful
Drawbacks:÷ More expensive than S7-300, but cheaper in the long run…÷ Larger in size
RIO units – Safe area Protection level IP20 Operating range 0...60°C (-20...60°C) Redundant connection (for H CPUs) I/O Module Redundancy (1 Sensor -> 2 Modules) Modularly expandable Max. 12 I/O modules per station I/O Modules with comprehensive diagnostics
Power supply Interface module for Profibus DPIM153-2
I/O moduleExpandablebackplane
Aluminium rail
RIO units – Ex zone 2 or 1 - ET200iSP ET200iSP
– Specifications:- AC 85 … 264VAC- -20C … +70C - ATEX II 2 G (1)
Ex de [ia/ib] IIC T4
– Profibus DP:- Intrinsic safe communication Ex ib- Plug/unplug under Ex conditions- Single (or redundant) communication- Active EOL compensation
– Power supply- Ex d- Redundant power
RIO units ET200iSP
– Possible housing:- EEx e for Zone 1 and 2- Wall mount- Stainless steel: DIN 1.4404 1.5 mm- Non-Corrosive materials- Expandable up to 32 modules
RS485-iS cables withBuccaneer
Cause & Effect Requirements:
– Flexibility– Online verification– SIL demands
Safety Matrix
Benefits
The SIMATIC Safety Matrix as - Engineering Tool- Real time Viewer
Configuration of the Safety Functions with the Cause & Effects Method
Automatic TÜV-certified Creation of the Safety Logic from the Cause & Effect matrix
Easy Configuration without special Programming Knowledge
Configuration, auto-generation and diagnostic tool for SIL3 application:
First-in alarm display and saving Integrated commands: bypass, reset, override, parameter modification Sequence of event display and savings Operator interventions Automatic version tracking Automatic documentation of modifications
Benefits
HMI
HMI
HMIHMI Screens
Alarm Screen – YA711
Process Screens
Trending
HART Interface
Simatic Process Device Manager HART Instrument Validation
Agenda:• One minute about Roxel• Short introduction to Safety Integrity Levels - SIL• SIL in Programmable Electronic Systems (PES):
– Rules and regulations– Project execution and verification– Programming tools– Equipment
PCS 7 systems
Technology:– Siemens S7-400 PLC
Software:– Siemens PCS 7– Safety Matrix
Benefits:– Less programming– More configuring– Simplified documentation
Drawbacks:– More expensive– Cheaper in the long run
Documentation DNV-OS-D202 October 2008 - AUTOMATION, SAFETY, AND TELECOMMUNICATION SYSTEMS
– System Availability: R0 - Continuous available
– Certification and Classification requirements:
Documentation
DocumentationNODE Documentation according to Safety Validation and Assessment plan
Section 1, General:
Functional Specification, FS, FDS, (SRS and SAR)Node Plan and Progress Reports Revision recordCPI, Computer Point IndexC&E's, SCD's, SEQUENCE LOGIC/SFC'sSerial Links SpecificationsStatic Pictures Design BasisChange LogOther technical basis documents (MOM, TQ etc)Node software backup
Section 2, Hardware:
System Block DiagramGeneral Arrangement DrawingsPower Distribution DrawingsHardware Typicals Equipment Lists / SPIRInterface and Connection DrawingsX-Wiring and Circuit Diagrams
Secton 3, Test Dossier:
Test procedure (NORDTEST checklists)Certificates, Approvals and Statements.HW Test SheetsObject Test Report / Sheets Application Test ReportNode to node communication Test SheetsTest Reports for Test of Serial LinksPunch log
DocumentationNORSOK Z-015:
1. Overall frame GA‘s.2. All junction box/enclosure GAs.3. Hydraulic Schematic Diagram if applicable.4. Electrical Schematic Diagram.5. Any Mimic Panel Drawings.6. System Block Diagram.7. Electrical Interconnection Diagrams and/or cable
schedules for all system/subsystems.8. Tubing Diagram if applicable.9. Operations Manuals for all system/subsystems.10. Maintenance Manuals for all system/subsystems.11. Recommended spares for all system/subsystems.12. Certification for all systems/subsystems including but not limited to:-
Hazardous area inspection schedule.Instructions for safe use.Special conditions of use.Any calculations to allow correct installation of
equipment in a hazardous area.Hazardous area equipment schedule.
13. EC declaration of conformity for all system/subsystems. (European directive).14. Interface Drawings.15. FAT/SIT procedures.16. Manufacturers and vendor test results for cabling used (IR and continuity).17. Manufacturers and vendor test results fibre cabling.18. All calculations and documentation pertaining to the achieved SIL rating.
DocumentationNode book:
Documentation of relevant documents:
- Design documents and drawings- Specifications- Procedures- Change logs- Test reports
Purpose:
- System documentation- Conformity- Traceability
DocumentationOther relevant activities:
- QA plan and QA activity list - Documentation review (Spec/C&E)- Technical reviews, HW, SW and HMI- Configuration Review- Participation in HAZID/HAZOP- Validation of procedures FAT/IAT- Internal Roxel procedures
- Experience transfer
Instrumentation
Ea 8-23°
General:• All sensors SIL 2 (not Gamma), exd, exi
• Flow• Level• Temp.• Pressure• Mass
• Prosess Connection in SS316 (wet parts)• All type Signals incl.
• 4-20mA• Field bus (FF, PA, Hart)
• All sensors can be delivered w/options• Housing (ss 316)• Hasteloy c, titan, monel (wet parts)• Diagnostics tool kit
Valves and actuators
General:• SIL 2, exd, exi, exm,
• Prosess Connection in brass, SS316 (wet parts)• Signals that can be provided
• 3-15 psi• 4-20mA• Field bus (PA, AS)• «most common supplies» (AC/DC)
• Can be delivered w/options• Housing (ss 316)• Hasteloy c, titan, monel (wet parts)