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Implementing Safety

Instrumented

Burner Management Systems:

Challenges and Opportunities

Mike Scott, PE, CFSE

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

2

SI-BMS

Templatization =

Significant Cost /

Schedule Savings

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

operations

Applying the safety lifecycle to

existing brownfield BMS

installations typically results in

capital projects to close gaps

Capital Project Chaos!

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???

5

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???

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

• 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???

7

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

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

improvement gains quickly realized

by using dedicated teams executing

standard designs with automated

testing

Projects moving forward

$

10

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%

11

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Questions?

mike.scott@aesolns.com

1-907-301-3111