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 - 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 Mike Scott, PE, CFSE • IEC 61511 committee member • ISA Safety and Security Division Director - Elect Executive Vice President • Global Process Safety ISA 2015 PCS Symposium Safety Chair • ISA Training Course Developer / Instructor • ISA Fellow 2
SI-BMS Templatization = Significant Cost / Schedule Savings
Challenges & Opportunities Applying the safety lifecycle to existing brownfield BMS installations typically results in capital projects to close gaps • 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 Capital • Typically risk analysis will result in Project missing SIFs, improperly defined SIFs and orders of magnitude differences Chaos! in SIL targets for like SIFs / unit operations
Safety Lifecycle Tasks Process Hazard Analysis Layer of Protection Analysis What if I could Safety Integrity Level (SIL) Selection COPY and PASTE??? Safety Requirements Specification SIL Calculations & Verification Functional Test Plans Functional Safety Assessments¹ ¹ Stages 1, 2, & 3 5
Instrumentation & Control System Design Tasks • • Instrument Approved Vendors List in line Control Panel Design w/ Bill of Materials with SIL Calculation assumptions • Control Panel Internal Wiring • Instrument Datasheets • Field Wiring (Loops / Swing Arms / • Instrument Index Schematics) • • I/O List Control System Architecture Diagram • • What if I could Control Panel Design w/ Bill of Materials Instrumentation and / or Electrical Installation Details • Control Panel Internal Wiring • Cable / Conduit Block Diagram • Field Wiring (Loops / Swing Arms / • COPY and PASTE??? Schematics) Cable Schedule • • Control System Architecture Diagram Software Requirements Specification • • Instrumentation and / or Electrical Logic Solver Configuration Installation Details • Logic Solver Simulation Logic • Instrument Approved Vendors List in line • Local Flat Panel Configuration with SIL Calculation assumptions • Historian Configuration • Instrument Datasheets • Remote BPCS HMI Configuration • Instrument Index • Factory Acceptance Test Procedure / • I/O List Testing • Site Acceptance Test Procedure / Testing • Commissioning Test Procedures / Testing 6
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 What if I could • Spare Parts in Stores per Mean Time To Repair assumptions in SIL Calculations COPY and PASTE??? • 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 7
SI-BMS Templatization Methodology Intelligent Engineering Drawings Store Templates Auto Auto Configure Test Safety Safety / Software Configuration Lifecycle Requirements File Management Toolkit Store Templates Test Engine Safety PLC Auto MoC Results 8
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 9
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 outage/TAR schedule is safely achieved • Quality – Continuous Projects moving forward improvement gains quickly realized by using dedicated teams executing standard designs with automated testing 10
COST SAVINGS!!! x → 60% Safety Lifecycle x → 75% I&C System Design x → 70% O&M Activities x → 35% TOTAL x → 60% Traditional project execution What if I could COPY and PASTE??? 11
Questions? mike.scott@aesolns.com 1-907-301-3111 Standards Certification Education & Training Publishing Conferences & Exhibits
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