安全儀表系統(tǒng)簡介

1、2004-04-28 U.Schuenemann安全儀表系統(tǒng)簡介1Introduction to E&I Safety Instrumented Systems (SIS)電儀安全儀表系統(tǒng)電儀安全儀表系統(tǒng)(SIS) 介紹介紹2004-04-28Ulrich Schuenemann BYC NanjingBYC 南京南京尤瑞奇尤瑞奇 舒曼舒曼CTA DepartmentE&I maintenance EOEG電儀維修電儀維修EOEG CTA部部2004-04-28 U.Schuenemann安全儀表系統(tǒng)簡介2lControl loops 控制回路控制回路 DCS lMonitor

2、ing functions 檢測功能檢測功能DCSlInterlocks needed for smooth operation DCS, (ESD) 順利運行所需的連鎖順利運行所需的連鎖lInterlocks related to plant Safety ESD與裝置安全有關(guān)的連鎖與裝置安全有關(guān)的連鎖There are different E&I functions 電儀功能各不相同電儀功能各不相同2004-04-28 U.Schuenemann安全儀表系統(tǒng)簡介3What are E&I S.I.S. 什么是電儀什么是電儀S.I.S?E&I Safety Instr

3、umented Systems (S.I.S.):E&I Safety Instrumented Systems (S.I.S.): 電儀安全儀表系統(tǒng)電儀安全儀表系統(tǒng)lS.I.S. preventS.I.S. prevent 安全儀表系統(tǒng)用于防止：安全儀表系統(tǒng)用于防止：personnel injurypersonnel injury 人身傷害或人身傷害或 environmental damageenvironmental damage 環(huán)境破壞環(huán)境破壞caused by a not tolerable fault state of the caused by a not tolerab

4、le fault state of the plant plant 由裝置的不可接受的故障所造成由裝置的不可接受的故障所造成 lS.I.S. are defined in the Safety Review S.I.S. are defined in the Safety Review Step 2.Step 2. 安全儀表系統(tǒng)是在安全風險評估的第二步中安全儀表系統(tǒng)是在安全風險評估的第二步中定義的定義的2004-04-28 U.Schuenemann安全儀表系統(tǒng)簡介4Classification of E&I functions 電儀電儀功能的分類功能的分類2004-04-28 U.S

5、chuenemann安全儀表系統(tǒng)簡介5Definition of SIS: Safety Review step 2SIS的定義的定義: 安全審查步驟安全審查步驟2 SEVERITY 嚴重性嚴重性S1 Potential for one or more fatalitiesS2 Potential for one or more serious injuries (irreversible)S3 Potential for one or more lost time injuriesS4 Potential for minor injuries, or irritationE&I SI

6、S can be used for “risk class B and C”.電儀電儀SIS可用于可用于 “B級和級和C級風險級風險”SeverityProbability嚴嚴重性概率重性概率S1S2S3S4P0 (=1/y)ABDEP1 (1/10y)A/BBEEP2 (1/100y)BCEFP3 (1/1.000y)CDFFP4 (1/10.000y)EFFF2004-04-28 U.Schuenemann安全儀表系統(tǒng)簡介6Example: E&I Safety Review 2 Checklist實例實例: 電儀安全審查電儀安全審查2檢查清單檢查清單2004-04-28 U.Sc

7、huenemann安全儀表系統(tǒng)簡介7Failures of a S.I.S. S.I.S的故障的故障lActive errortriggers off the safety function for no reasonplant is switched back to safe operationreduction of production availability 有源故障有源故障-無緣無故觸發(fā)安全功能無緣無故觸發(fā)安全功能-裝置切回到安全運行裝置切回到安全運行-生產(chǎn)運行可用率降低生產(chǎn)運行可用率降低lPassive error 無源故障無源故障inhibits the required sa

8、fety function plant continues operation although it should be switched offimpacting the process safetyadversely affecting the safety function 對安全功能產(chǎn)生不利影響對安全功能產(chǎn)生不利影響no adverse effect onthe safety function對安全功能無不利影響對安全功能無不利影響Failure 故障故障Time-averaged probability for a passive Time-averaged probability

9、 for a passive fault : fault : PFD “Probability of Failure on Demand” PFD “Probability of Failure on Demand” 無源故障的時間平均可能性無源故障的時間平均可能性: :PFD”PFD”指令故障的可能性指令故障的可能性“ “2004-04-28 U.Schuenemann安全儀表系統(tǒng)簡介8Components of a SIS SIS的組分的組分Shut-Down SystemShut-Down System 停車系統(tǒng)停車系統(tǒng)Logic in Failsafe PLC or Hardwired

10、 system在故障安全型可編程控制器或硬接線系統(tǒng)中的邏輯Redundant sensors冗余的傳感器Valve閥門Solenoid valve電磁閥Instrument air supply 儀表氣源Rack Room Rack Room 機柜間機柜間Field Field 現(xiàn)場現(xiàn)場2004-04-28 U.Schuenemann安全儀表系統(tǒng)簡介9Passive Faults of sensors and actuators傳感器和致動器的無源故障傳感器和致動器的無源故障mass flow meter mass flow meter after pressure after pressur

11、e pulsepulse壓力脈沖下游的壓力脈沖下游的質(zhì)量流量計質(zhì)量流量計lost control valve plugcontrol valve plug, damaged by cavitationrestriction orifice, deformed by flow限流孔板限流孔限流孔板限流孔板, 流量造成的變形流量造成的變形調(diào)節(jié)閥閥塞調(diào)節(jié)閥閥塞,空穴造成的損壞空穴造成的損壞2004-04-28 U.Schuenemann安全儀表系統(tǒng)簡介10Some mathematics 一些算法一些算法TITest Interval between functional tests of SIS,

12、time needed to discover dangerous faults SISSIS功能測試之間的時間間隔功能測試之間的時間間隔, , 發(fā)現(xiàn)危險故發(fā)現(xiàn)危險故障需要的時間障需要的時間MTBFMean Time Between Failure of an equipment 設(shè)備故障之間的平均時間設(shè)備故障之間的平均時間l = 1/ MTBFfailure rate 故障率故障率Pf (t)Probability of failure (to function). For constantfailure rates l :Pf (t) = (1 e-l t ) 故障概率故障概率( (對功能

13、而言對功能而言).).恒定故障率恒定故障率 l : P l : Pf f (t) = (1 e(t) = (1 e-l t-l t ) ) PFDProbability of Failure on Demand= Pf (t) , time averaged over test interval TI 指令故障概率指令故障概率= P= Pf f (t) , (t) , 時間間隔時間間隔TITI的平均的平均時間時間 PFD = 1/TI 0TI Pf (t) dt2004-04-28 U.Schuenemann安全儀表系統(tǒng)簡介11PFD Probability of Failure on Dem

14、andPFD指令故障概率指令故障概率 Probability Pf(t) for finding equipment in dangerous fault state after time t has passed since last functional test自上次功能試驗以自上次功能試驗以來經(jīng)過時間來經(jīng)過時間 t 后后 ,發(fā)現(xiàn)設(shè)備處在危發(fā)現(xiàn)設(shè)備處在危險故障狀態(tài)的概險故障狀態(tài)的概率率.Pf (t) = (1 e-l t ) time average 時間平均值時間平均值PFD Probability of Failure on demandPFD depends on failure

15、rate of equipment AND test interval.PFD取決于設(shè)備取決于設(shè)備ANDAND試驗間隔的故障率試驗間隔的故障率2004-04-28 U.Schuenemann安全儀表系統(tǒng)簡介12Calculation of PFD PFD的計算的計算lPFD calculation of an individual equipment easy, if you havetest interval failure rate (given by supplier)如有試驗間隔和故障率如有試驗間隔和故障率(供貨方提供供貨方提供), 則某個設(shè)備的則某個設(shè)備的PFD計算就不難計算就不難l

16、PFD-calculation for more complex configurations (2oo3 etc. ) can be done using simple statistical models: Good for comparing different configurations.用簡單的統(tǒng)計模型可進行較復雜的配置用簡單的統(tǒng)計模型可進行較復雜的配置(2003等等)的的PFD計算計算lFor SIS: PFD of field domain and control domain must be added. 對于對于SIS: 必須加上磁場域和控制域的必須加上磁場域和控制域的PF

17、D PFDSIS = PFDsensor + PFDPLC + PFDactuator 2004-04-28 U.Schuenemann安全儀表系統(tǒng)簡介13Calculation of PFD the problemsPFD的計算的計算問題問題lPFD data for field instruments usually not very reliable(not experimentally verified for chemical environment). 用于現(xiàn)場儀表的用于現(xiàn)場儀表的PFD數(shù)據(jù)通常不是很可靠數(shù)據(jù)通常不是很可靠(對于化學對于化學環(huán)境未經(jīng)試驗驗證環(huán)境未經(jīng)試驗驗證).lCo

18、ntribution to Failure Probability (PFD):對故障概率對故障概率的影響因素的影響因素lcalculated values for PFD: often not very accurate. lPFD計算值計算值: 經(jīng)常不太準經(jīng)常不太準Field InstrumentsField Instruments85 % 85 % 現(xiàn)場儀表現(xiàn)場儀表Logic SolverLogic Solver(failsafe PLC(failsafe PLC)15 %15 %邏輯解答器邏輯解答器( (故障保護故障保護PLC)PLC)2004-04-28 U.Schuenemann安

19、全儀表系統(tǒng)簡介14“SIL” requirements for SIS SIS的的“SIL”要求要求Safety Integrity Level(SIL)安全一體化水安全一體化水平平Probability of Failure on Demand (PFD)指令故障概率指令故障概率1 0.10 - 0.01operating and monitoring functions 運行和檢測功能運行和檢測功能20.01 - 0.001SIS (“Class A functions”)SIS (“A級功能級功能”)30.001 - 0.0001For SIS: international and BA

20、SF standards request SIL 2 or SIL 3.對于對于SIS: 國際標準和巴斯夫標準要求國際標準和巴斯夫標準要求SIL2 或或 SIL3.2004-04-28 U.Schuenemann安全儀表系統(tǒng)簡介15How to meet “SIL” requirements 如何滿足如何滿足“SIL”要求要求Right Instruments: from BASF standard list (field proven) or certified 儀表正確儀表正確 : 來自巴斯夫標準清單或核準者來自巴斯夫標準清單或核準者 (SIL 2, TUV certificate,) D

21、evices without systematic design or manufacturing errors which can lead to common failure of redundant channels at the same time. 2. Right Design: Redundancy, Diversity. Use design typicals in BASF standard. 設(shè)計正確設(shè)計正確: 冗余冗余, 多樣性多樣性. 采用巴斯夫標準中的典型設(shè)計采用巴斯夫標準中的典型設(shè)計 Redundant (and diverse) channels of senso

22、rs and actuators make system tolerant against single passive and active faults. 3. Testing, Maintenance : perform commissioning test and periodic functional proof tests of SIS. 測試測試,維護維護: 進行進行SIS調(diào)試試驗和定期的功能驗證試驗調(diào)試試驗和定期的功能驗證試驗 In order to discover passive faults of SIS. Test interval depends on design.

23、 2004-04-28 U.Schuenemann安全儀表系統(tǒng)簡介16BASF Global Standard Lists 巴斯巴斯夫全球標準清單夫全球標準清單BASFs Standard DevicesBASFs Standard Deviceshave passed extensive laboratory have passed extensive laboratory testing acc. to IEC770 at BASF, testing acc. to IEC770 at BASF, Ludwigshafen.Ludwigshafen.are field-proven in

24、non-safety related are field-proven in non-safety related applications.applications.have shown no passive fault during field have shown no passive fault during field testing (at least 10 devices monitored testing (at least 10 devices monitored for 1 year).for 1 year).巴斯夫的標準裝置巴斯夫的標準裝置已通過廣泛的實驗室試驗已通過廣泛

25、的實驗室試驗, ,符合路德維希符合路德維希港巴斯夫港巴斯夫IEC770IEC770標準標準. .在相關(guān)危險應(yīng)用中經(jīng)過現(xiàn)場驗證在相關(guān)危險應(yīng)用中經(jīng)過現(xiàn)場驗證. .在現(xiàn)場測試中未出現(xiàn)無源故障在現(xiàn)場測試中未出現(xiàn)無源故障 ( (至少至少1010臺臺裝置被檢測了一年裝置被檢測了一年). ).2004-04-28 U.Schuenemann安全儀表系統(tǒng)簡介17Design: Typicals for SIL2 and SIL3 設(shè)計設(shè)計: SIL2 和和 SIL3的典型之處的典型之處SIL2:lsingle channel design 1oo1can be usedl12 month test inter

26、vall可使用單信道設(shè)計可使用單信道設(shè)計1oo1l12個月的試驗間隔個月的試驗間隔SIL3:SIL3:single channel design not allowed single channel design not allowed at least: 2 sensors (1oo2) and 2 at least: 2 sensors (1oo2) and 2 actuators.actuators.12 month test interval.12 month test interval.不允許單信道設(shè)計不允許單信道設(shè)計至少至少2 2個傳感器個傳感器(1(1oo2)oo2)和和2 2個

27、致動器個致動器1212個月的試驗間隔個月的試驗間隔2004-04-28 U.Schuenemann安全儀表系統(tǒng)簡介18PFD of different Architectures 不同不同結(jié)構(gòu)的結(jié)構(gòu)的PFDWhats the best configuration: 1oo1, 1oo2, 2oo2, 2oo3, 2oo4, ?最佳組態(tài)是什么最佳組態(tài)是什么?Consider: “failure on demand”-rate (affects plant safety) “false trip”-rate (affects plant availability)須考慮須考慮: “指令故障指令故障

28、”率率 (影響裝置安全影響裝置安全) “誤跳閘誤跳閘”率率 (影響裝置可用率影響裝置可用率)2oo22oo2 / 2oo41oo12oo31oo31oo2 / 2oo42oo31oo31oo21oo12004-04-28 U.Schuenemann安全儀表系統(tǒng)簡介19Commissioning & Proof Testing of E&I S.I.S.安全儀表系統(tǒng)的調(diào)試及試驗安全儀表系統(tǒng)的調(diào)試及試驗 All International and BASF standards for SIS require a All International and BASF standard

29、s for SIS require a documented testsdocumented tests所有有關(guān)的國際標準或所有有關(guān)的國際標準或BASFBASF標準均要求對安全儀表系統(tǒng)進行有文檔標準均要求對安全儀表系統(tǒng)進行有文檔記錄的測試記錄的測試lperiodic proof tests periodic proof tests 周期性的試驗周期性的試驗lcommissioning test before startup commissioning test before startup 開車前的調(diào)試開車前的調(diào)試 Objective for Commissioning Test: Objec

30、tive for Commissioning Test: 調(diào)試的目的是為了檢查：調(diào)試的目的是為了檢查： design according to Safety Review 2 design according to Safety Review 2 設(shè)計遵照安全風險評估第二步所要求設(shè)計遵照安全風險評估第二步所要求 installation ok installation ok 安裝正確安裝正確 parameter settings ok parameter settings ok 參數(shù)設(shè)置無誤參數(shù)設(shè)置無誤 function of instruments (sensors and actuator

31、s) ok function of instruments (sensors and actuators) ok 儀表功能（傳感器儀表功能（傳感器, ,執(zhí)行器）均正確無誤執(zhí)行器）均正確無誤 logic action correct logic action correct 邏輯動作正確邏輯動作正確Commissioning test of S.I.S. will be main task for CTA PM during Commissioning test of S.I.S. will be main task for CTA PM during commissioning of missioning of plants.在裝置調(diào)試期間，安全儀表系統(tǒng)的調(diào)試是電儀經(jīng)理的主要任務(wù)在裝置調(diào)試期間，安全儀表系統(tǒng)的調(diào)試是電儀經(jīng)理的主要任務(wù)2004-04-28 U.Schuenemann安全儀表系統(tǒng)簡介20Responsibilities 職責職責CTA manager CTACTA經(jīng)理經(jīng)理Plant Manager裝置經(jīng)裝置經(jīng)理理Project team項目項目組組prepare prepare procedures procedures for for co