WIB Functional Safety

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1 WIB Functional Safety From Interpretation to successful Implementation March 21, 2013 Leon Heemels

2 Functional Safety workgroup Functional Safety workgroup Scope of this workgroup Participants Workgroup Achievements Workgroup Charter From Interpretation to successful Implementation Summary

3 Functional Safety workgroup Scope and Boundaries of this workgroup The w.g. will only consider the functional safety standards which will impact Process Industry Out of scope ATEX, Electrical Safety, PED, Evaluation of equipment

4 Functional Safety workgroup Participants 1. SHELL Global Solutions 2. DSM 3. Dow Benelux 4. DuPont 5. ExxonMobil 6. AkzoNobel O&S 7. KPE-Q8 8. SABIC 9. Aramco Overseas Company 10. BP 11. M+W 12. Namur 13. EdeA 14. Solvay 15. Technip 16. ErRakal 17. OCI 18. Cargill

5 Functional Safety workgroup Participants Aits Willem KPE-Q8 Bij van der Menno Technip Dongen Hans van DUPONT Hablawetz Dirk BASF NAMUR Heemels Leon DSM Chairman Heijnen Math OCI Nitrogen Hekker Hidde M+W Hinssen Henk PRIV Kaijser Kees Dow Kerf Dominic de Cargill New Koeken Tom EdeA Kruitz Karel ErRaKal B.V. Louisse Mart ARAMCO Muijnck Ab de BP-Ref Overhof Lou SABIC Schroers Bernd Bayer T S NAMUR Simons Maximillien Solvay Simdorn Johan EXXMOB Sneek John EXXMOB Soulje Geert J. DUPONT Stougie Richard Dow Teeuw Casper Shell Walsdorff Philippe Solvay Weiss Wim AKZONOB Kuperij Tom WIB Reporter

6 Functional Safety workgroup Workgroup Achievements Close cooperation with Namur WG FS The Need for Certified Field Instruments in SIS Applications WIB Application Note: AN , Aug 2004 Topic No 9: Testing and Diagnostics in Practice, November 2, 2003, by Jan Wiegerinck Shell Global Solutions Int. and Wijnand Bitter EXXONMobil Chemicals Liaison with Arbeids Inspektie Security in SIS Jan 11, 2012, comment on WIB- M 2784 X10- Process Control Domain-Security Requirements for vendors Topic No 4: Test procedures and test interval optimization in Practice May 24, 2005, by Berend Stam, Akzo Nobel Engineering, Leon Heemels, DSM Corporate SHE&M Skills Matrix and Competences (development) Guideline to determine if the Trip speed is SUFFICIENT Nov 12, 2010, by Leon Heemels and Lou Overhof Checklist Verification of SIF Design and Installation Oct 15, 2007, by Leon Heemels AN WIB Application Note-How to deal with Expiring SIL certificates Jan. 19, 2012, by WIB FS WG Maintenance Override - Survey result Jan. 19, 2012, by Ph. Walsdorff WIB Failure rate Database ( development)

and Wijnand Bitter EXXONMobil Chemicals Liaison with Arbeids Inspektie Security in SIS Jan 11, 2012, comment on WIB- M 2784 X10- Process Control Domain-Security Requirements for vendors Topic No 4:

7 Functional Safety workgroup Topics Current Workgroup Charter FS in Batch operation (Overrides, variable Trip S/P) Review MT SIL Certification Validity Equipment life expectancy, obsolescence Competence management Prior use/proven in use Security in SIS Energize to trip in PFD calculations Burner management systems WEID ( Werkgroep Eigen Inspectie Diensten) Alarm Management versus FS

obsolescence Competence management Prior use/proven in use Security in SIS Energize to trip in PFD

8 From Interpretation to successful Implementation From Interpretation to successful Implementation

9 From Interpretation to successful Implementation Importance of: Hazard and Risk assessment Safety Requirement Specification SRS Effectiveness Verification Pitfalls Overvaluation PFD calculations Prior use Common mode effects Testing

Requirement Specification SRS Effectiveness Verification

10 From Interpretation to successful Implementation Hazard and Risk assessment A not identified scenario will not be safeguarded! A competent multidisciplinary team is key Installing a safety provision is repairing the risk

11 From Interpretation to successful Implementation Safety Requirement Specification SRS General SRS for the SIS: energize or de-energize to trip requirements for overrides (MOS, POS) identification of the dangerous combinations of output states of the SIS which need to be avoided (System HAZOP) Specific SRS for the SIF Sensor Requirements Logic Solver Requirements Final Element Requirements Process safety time vs. SIF Response time

combinations of output states of the SIS which need to be avoided (System HAZOP) Specific SRS for the SIF

12 From Interpretation to successful Implementation Effectiveness = Success to reach the Safe State within the Process Safety Time Effectiveness of the sensor(s) Location Response time (sample line, sensor) Type and principle of measurement Wet part conditions (fouling, erosion, crystallization, freezing, polymerization etc.) Effectiveness of the Final Element(s) Location Response time (actuator travel time, process response time) Valves under demand conditions FC Acceptable Leakage rate FO Minimum capacity Wet part conditions (fouling, erosion, crystallization, freezing, polymerization etc.)

13 Verification From Interpretation to successful Implementation

14 From Interpretation to successful Implementation Pitfalls Overvaluation PFD calculations Dependent on large variation in failure data (in-accurate) Compensation poor reliability by decrease Proof-test interval Sound design is more important than calculation! Prior use Difficult to meet the IEC Some companies introduced the use of expert statements which have to be evaluated every 2 years In the MT IEC61511 some new methods will come available to reach prior use status (H1 H2 Route, NE 130) Common mode effects Use of the similar instruments in redundant systems (interaction) Supporting provisions (one tracing for 1oo2) Unwanted combinations on I/O Testing Awareness of technicians on SIL Importance of preventive maintenance

Prior use Difficult to meet the IEC 61511 Some companies introduced the use of expert statements which have to be evaluated every 2 years In the MT IEC61511 some new methods will come

15 Summary SIS Life Cycle Phases according IEC is a good basis for endusers This approach is the basis for almost all WIB members Be aware of the many Pitfalls in the lifecycle of an effective SIF WIB WG FS is an important platform to share user experiences KISS Keep Thinking

aware of the many Pitfalls in the lifecycle of an effective SIF WIB

WIB Mini-Seminar, The Hague (21 st of March 2013) An update from the Control Systems Working Group

WIB Mini-Seminar, The Hague (21 st of March 2013) An update from the Control Systems Working Group Kees Biesheuvel, DOW Product Manager MOD5 Engineering Solutions Jos Menting, Laborelec Belgium, CTO The