Instrumented Burner Management Systems: Challenges and - - PowerPoint PPT Presentation

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Instrumented Burner Management Systems: Challenges and - - PowerPoint PPT Presentation

Mar 24, 2023 95 likes •228 views

Implementing Safety Instrumented Burner Management Systems: Challenges and Opportunities Mike Scott, PE, CFSE Standards Certification Education & Training Publishing Conferences & Exhibits Presenter B.S. Mechanical Engineering

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Standards Certification Education & Training Publishing Conferences & Exhibits

Implementing Safety Instrumented Burner Management Systems: Challenges and Opportunities

Mike Scott, PE, CFSE

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Presenter

Mike Scott, PE, CFSE

Executive Vice President Global Process Safety

  • B.S. Mechanical Engineering - University of Maryland
  • Masters of Engineering - University of South Carolina
  • Licensed Professional Engineer - AK, GA, SC, and IL
  • Certified Functional Safety Expert (CFSE)
  • Voting member of ISA S84 committee on

Electrical/Electronic/Programmable Electronic Systems (E/E/PES) for Use in Process Safety Applications

  • Chairman of the ISA S84 Working Group on

Performance Based Fire & Gas Systems

  • ISA S84 BMS sub-committee member and liaison to

the America Boiler Manufacturer’s Association (ABMA) and NFPA 86

  • IEC 61511 committee member
  • ISA Safety and Security Division Director - Elect
  • ISA 2015 PCS Symposium Safety Chair
  • ISA Training Course Developer / Instructor
  • ISA Fellow

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SI-BMS Templatization = Significant Cost / Schedule Savings

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Challenges & Opportunities

  • Possibly new field devices
  • New Safety PLC
  • If BMS upgrades treated as stand

alone projects, it will be costly and take many years to remove risk from the business

  • Typically risk analysis will result in

missing SIFs, improperly defined SIFs and orders of magnitude differences in SIL targets for like SIFs / unit

  • perations

Applying the safety lifecycle to existing brownfield BMS installations typically results in capital projects to close gaps

Capital Project Chaos!

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SLIDE 5

Safety Lifecycle Tasks

Process Hazard Analysis Layer of Protection Analysis Safety Integrity Level (SIL) Selection

Safety Requirements Specification

SIL Calculations & Verification Functional Test Plans Functional Safety Assessments¹

¹ Stages 1, 2, & 3

What if I could COPY and PASTE???

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Instrumentation & Control System Design Tasks

  • Instrument Approved Vendors List in line

with SIL Calculation assumptions

  • Instrument Datasheets
  • Instrument Index
  • I/O List
  • Control Panel Design w/ Bill of Materials
  • Control Panel Internal Wiring
  • Field Wiring (Loops / Swing Arms /

Schematics)

  • Control System Architecture Diagram
  • Instrumentation and / or Electrical

Installation Details

  • Instrument Approved Vendors List in line

with SIL Calculation assumptions

  • Instrument Datasheets
  • Instrument Index
  • I/O List
  • Control Panel Design w/ Bill of Materials
  • Control Panel Internal Wiring
  • Field Wiring (Loops / Swing Arms /

Schematics)

  • Control System Architecture Diagram
  • Instrumentation and / or Electrical

Installation Details

  • Cable / Conduit Block Diagram
  • Cable Schedule
  • Software Requirements Specification
  • Logic Solver Configuration
  • Logic Solver Simulation Logic
  • Local Flat Panel Configuration
  • Historian Configuration
  • Remote BPCS HMI Configuration
  • Factory Acceptance Test Procedure /

Testing

  • Site Acceptance Test Procedure / Testing
  • Commissioning Test Procedures / Testing

What if I could COPY and PASTE???

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Operations & Maintenance Tasks

  • Functional Test Plans, Instrument Calibration, Valve Leak Testing

loaded and scheduled into the site Computerized Maintenance Management System (CMMS) per Proof Test Coverage assumptions in SIL Calculations

  • Spare Parts in Stores per Mean Time To Repair assumptions in SIL

Calculations

  • Operations / Maintenance Trained on new SI-BMS
  • Program / personnel in place to track Time in Bypass, Demand

Frequency, Cause Frequency, Dangerous Undetected Failures, and Late / Incomplete Testing of SIFs per IEC 61511 requirements

What if I could COPY and PASTE???

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Configuration File Safety / Software Requirements Auto Configure Safety PLC

SI-BMS Templatization Methodology

Intelligent Engineering Drawings Store Templates Safety Lifecycle Management Toolkit Store Templates Auto Test Test Engine Results Auto MoC

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SI-BMS Templatization Execution

  • Templates – Leverage

established design standards to ensure high quality, consistent deliverables

  • Testing – Develop design

methodology that maximizes automated testing for critical information capture

  • Team – Dedicated high

performing small teams to execute SI-BMS Upgrades

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SI-BMS Templatization Savings

  • Cost – Using SI-BMS approach

leveraging small, high performing teams to implement standard templates and testing schemes

  • Schedule – Operations

approval of entire SI-BMS functionality prior to FAT to ensure

  • utage/TAR schedule is safely

achieved

  • Quality – Continuous

improvement gains quickly realized by using dedicated teams executing standard designs with automated testing Projects moving forward $

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COST SAVINGS!!!

x → 60%

Traditional project execution What if I could COPY and PASTE??? Safety Lifecycle I&C System Design O&M Activities TOTAL x → 75% x → 70% x → 35% x → 60%

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Standards Certification Education & Training Publishing Conferences & Exhibits

Questions? mike.scott@aesolns.com 1-907-301-3111