Scalable Process Safety

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Scalable Process Safety

Kevin CollotonTechnology Manager - Safety

Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 2

Agenda Sample

1. Process Safety Market

2. Safety Applications

3. Safety System Options


Process Safety Applications & Market

• Historically there are these major types of Process Safety Applications:– Emergency Shut Down (ESD) 41%– Fire & Gas (F&G) 24%– Critical Control (CC) 7%– Burner Management (BMS) 10%– Turbo Machinery 14%– Other

• Within these major industries– Oil & Gas– Refining– Chemical– Pharmaceutical– Power Generation


Process Applications & Safety

• Historically Process applications use two Automation Systems to control the site / application.– BPCS Basic Process Control System (DCS)– SIS Safety Instrumented System

• In Process Control it is common that the SIS NEVER performs!– If the BPCS operates without faults or problems, the SIS may

never intervene / take action.BUT– If the BPCS fails and is unable to perform, the SIS MUST

work correctly! Not to control, but to shutdown in a controlled manner.Because if it doesn’t, will other measures be sufficient?• LOPA – Layers of Protection Analysis


SIS Safety Instrumented System

• Because of this importance many years ago industry best practice determined that SIS features implement / satisfy key requirements:– Separation and Diversity being important

• Physical separation from the BPCS– To reduce the risk of an external single event affecting both

systems• Diversity from the BPCS

– To reduce the risk of an internal event affecting both systems (common cause due to design commonality)

• High Availability– To reduce / eliminate nuisance trips– An unexpected / untimely shutdown could be hazardous


Safety Applications

High Demand Low DemandMachine Safety

• Safety Demand <1 hrISO 13849IEC 62061

Process Safety• Safety Demand 1 yr >

IEC 61511

Sector StandardsEN 298, 746, 50156

NFPA 85, 86More ….


Low Demand Safety Dynamics

• Of the Traditional Process Safety Applications:– Emergency Shut Down (ESD)– Fire & Gas (F&G)– Critical Control (CC)– Burner Management (BMS)– Turbo MachineryThese three process safety applications virtually always use a well recognized & reputable SIS Vendor.– Diversity is critical– Scalable safety – Scalable size– High Availability is typically required

Low Demand


Safety System Enhancements

• Over the last decade significant new safety technologies– SIL 3 rated communications (Black Channel)– Common communication protocols– Varying levels of software compatibility between the BPCS and SIS– Varying levels of hardware compatibility between the BPCS and SIS


Example of modern Scalable SIS

• AADvance SIS– Scalable in size– Scalable in safety– Scalable in Availability

• Same components• CIP Communications

– Easy to communicate with the BPCS• Programmed with ISAGraph

Workbench

• Used in conjunction with a BPCS

1oo1 SIL2 CPUSimplex I/O

1oo2 SIL3 CPUSIL3 Duplex I/O

High Availability CPUHigh Availability I/O

2oo3 SIL3 TMR CPU SIL3 TMR I/O

Voting High Availability


Process Machinery?

• Of the Traditional Process Safety Applications:– Emergency Shut Down (ESD)– Fire & Gas (F&G)– Critical Control (CC)– Burner Management (BMS)– Turbo MachineryThese two applications often have different requirements– They typically don’t implement a BPCS and SIS– They often have safety demands at a higher rate than low demand

• Not machine safety (high demand), but more than process (low demand)– They often don’t require high availability solutions

– In Europe these applications need to consider the EU Machinery Directive. • The MD does not recognize IEC 61511 (process safety standard)• The MD only recognizes IEC 62061 or ISO 13849 – Machine Safety

Safety Applications New Considerations


11

High Demand Low DemandMachine Safety

• Safety Demand >1 hrISO 13849IEC 62061

Process Safety• Safety Demand <1yr

IEC 61511

Sector StandardsEN 298, 746, 50156

NFPA 85, 86More ….

Machinery Directive (2006/42/EC)


Process Machines?

• Many have flame or heat control• All are portable (not built on site)• All have machine control elements, and also process control elements• A range of standard automation requirements, (size, speed, sophistication)• A range of safety requirements (simple safe off, zoning, simplex, high availability,

speed, SIL2, SIL3)

Furnace Thermoforming Turbo Machinery

Safety, just like Standard isn’t one size fits all.


Safety Applications

High Demand Low Demand


User / Customer Preferences

• Just as in standard automation, safety customers have choices in size, performance, availability, commonality (integration).

• Today users have world class solutions to choose from:• Diversity with communications integration• Fully integrated (software and hardware)

AADvance

Customers can leverage modern system flexibility to reduce plant complexity and improve compliance to virtually any safety

requirement

GuardLogix
