Safety Integrity Requirements in Turbine Control Retrofit Projects of Power Plant Turbo Machinery
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1 Power Gen Europe - June 2014 Safety Integrity Requirements in Turbine Control Retrofit Projects of Power Plant Turbo Machinery Answers for energy.
2 Contents Turbine Control Retrofit Benefits from Functional Safety Standards on Functional Safety Determining Risk Reduction at existing Turbo Machinery Summary Page 2 June 2014
3 Lifecycle of Components at Turbo Machinery Computers (3..5 years) Electronic Controllers (>7 years) Electronic I/O Components (>10 years) Sensor and Actuator Elements for Control & Protection (>20 years) Turbo Machinery ( years) Page 3 June 2014
4 Retrofit of Electronic Turbine Control Equipment Page 4 June 2014
5 Advanced performance through upgrading of mechanical-hydraulic equipment New speed transmitters for maximum control accuracy Installation of new electro-hydraulic-converters (EHC) for maximum control accuracy Conversion to individual valve control for maximum operating flexibility New 2-out-of-3 logic Turbine Trip Block to increase operating reliability Installation of new hydraulic lines, filters and hydraulic power supply stations to reduce maintenance New 2oo3 logic electronic overspeed protection - increase operational safety - reduces mechanical stress Page 5 June 2014
6 Retrofit of Hydraulic Protection Elements Overspeed Protection Overspeed Protection Axial Trust Protection Condenser Pressure Protection Electronic Turbine Protection Lube Oil Pressure Protection Turbine trip system Page 6 June 2014
7 Example: Retrofit of Overspeed Protection Circuit Existing Components Sensor Elements Mechanical Overspeed Rings Actuator Elements Mechanical Overspeed Trip System Page 7 June 2014
8 Example: Retrofit of Overspeed Protection Circuit Components after Retrofit Actuator Element 2oo3 Trip Block Turbine Controller Sensor Elements Electronic Speed Sensor 2 out of 3 Trip Block LP Ctrl. Vlv Protection Channel 1 Protection Channel 2 HP Ctrl. Vlv IP Ctrl. Vlv Protection Channel 3 Logic Solver Electronic Overspeed Protection Page 8 June 2014 Extraction Ctrl. Vlv
9 Retrofit of Turbine Protection Components or Loops Sensor Logic (Solver) Actuator Case 1: Replacement of (one) component as Spare Parts Case 2: Retrofit of Parts or the whole Protection Loop Application of Principals of Functional Safety Page 9 June 2014
10 Contents Turbine Control Retrofit Benefits from Functional Safety Standards on Functional Safety Determining Risk Reduction at existing Turbo Machinery Summary Page 10 June 2014
11 Benefits from Functional Safety Protection systems are essential to prevent hazards from harming people or causing damage. Functional Safety is the state of the art approach to ensure reliability of electronic protection systems Page 11 Page 11 June 2014
12 Contents Turbine Control Retrofit Benefits from Functional Safety Standards on Functional Safety Determining Risk Reduction at existing Turbo Machinery Summary Page 12 June 2014
13 Standards on Functional Safety Experience of the engineering community on digital electronic protection systems was pooled in the generic standard IEC Sector specific standards followed Process industry Machinery Railway Automobile Medical IEC SAFETY INSTRUMENTED SYSTEMS FOR THE PROCESS INDUSTRY IEC ISO SAFETY OF MACHINERY - CONTROL SYSTEMS EN RAILWAY APPLICATIONS - COMMUNICATIONS SIGNALLING AND PROCESSING SYSTEMS ISO ROAD VEHICLE - FUNCTIONAL SAFETY IEC MEDICAL DEVICE SOFTWARE Page 13 June 2014
14 Product specific standards for turbomachinery Turbomachinery Rotating machinery Gas turbines VDMA* 4315 Turbomachinery and generators Application of the principles of functional safety API th edition Machinery Protection Systems (in preparation) ISO Gas turbine applications Safety *) VDMA = German Association of Manufacturers of Machinery Page 14 June 2014
15 Risk Risk without Protective Measures Reduction of Process Risk with E / E / PE Systems Risk Reduction Reduction of Random Faults Reduction of Systematic Faults tolerable Risk Extra instrumentation & control logics added for protection are known as: Safety Instrumented Functions (SIFs) Page 15 June 2014
16 IEC / Defines lifecycle of Protection Systems Concept Risk Analysis Definition of Safety Requirements Planning of Operation Validation Planning Planning of Constr. / Comm. Design Phase Other Technology External Risk Red. Construction / Commissioning Overall System Validation Operation, Maintenance and Modification Responsibility of Operator Responsibility of Supplier Decommissioniong SIL required of a Safety Loop is derived from Risk Analysis Page 16 June 2014
17 Failure Rate λ IEC / SIL Level drives aspects of Safety Loop Design SIL Safety Integrity Level drives Required risk reduction Probability of failure on demand of SIF Hardware redundancy Specialized functions in control systems for protection Which aspects need independent (3rd party) checking Failure Rate λ of a Component Mechanical Components Sensor Logic Solver Actuator Electrical Components time (years) λs safe λdd dangerous detected λdu dangerous undetected PFD sensor + PFD logic solver + PFD actor = PFD SIF PFD allowable = f (SIL) PFD SIF < PFD allowable Page 17 June 2014
18 Contents Turbine Control Retrofit Benefits from Functional Safety Standards on Functional Safety Determining Risk Reduction at existing Turbo Machinery Summary Page 18 June 2014
19 Retrofit of Protection System with or without Principles of Functional Safety? Sensor Logic (Solver) Actuator or Selection of Certified Hardware Components Design of Hardware Loop according Principals of Functional Safety Usage of Certified Software Components Functional and Integrity Test during Shop Test Independent (3 rd Party) Check of Protection Loop Page 19 June 2014
20 Risk Analysis is Design Input for Retrofit of Turbine Protection Tender Offer Engineering FAT Comm Risk Analysis is Input for Tender Risk Analysis can be done in an early Phase of Basic Engineering Plant Operator is responsible for Project Specific Risk Analysis Operator Optional: RAMS Specialists with Experience in Risk Analysis Methods Optional: Turbine Specialist (Vendor) Page 20 June 2014
21 Evaluation by risk parameters Risk parameters: U - Unprotected accident rate W - Rate of occurrence of the hazard F - Probability of occupancy A - Probability of not avoiding the hazard V - Vulnerability General risk equation U = W x F x A x V See VDMA Standard Page 21 June 2014
22 S - Severity F- Probability of occupancy Av- Probability of unavoidance & vulnerability Determination of necessary risk reduction Risk reduction application of VDMA risk graph W - Rate of occurence of hazard Required SIL Source: VDMA a additional layer of protection required b application of SIF not appropriate Page 22 June 2014
23 Determination of necessary risk reduction SIL determination for Steam Turbine SIF VDMA Standard provides guidance on typical SIL values for steam turbines Page 23 June 2014
24 Example: Risk Analysis for Condensor Pressure Protection Risk Analysis results in SIL2 Protection Circuit Page 24 June 2014
25 Example: Risk Analysis for Condensor Pressure Protection Cause: Loss of cooling, air penetration in condenser, Result: Steam jet, immediate contact to hot steam, interruption of the casing, machine building fills up with steam Assessment: - Level of Danger: Death of 1 to max. 10 persons (S3) - Duration of exposure to the hazard: Risk >10% of operation time (F2) - Unavoidability: Probability of damage (with occupied work area) >10% (Av2) - Entry rate: <= 1/year (W2) Result: SIL3 Additional Measures?: High Availability of Cooling Water Pumps and Turbine and Bypass Trip in case Cooling Water Pumps fail Reduction to SIL2 VDMA is only a basis for project specific Risk Analysis Page 25 June 2014
26 Contents Turbine Control Retrofit Benefits from Functional Safety Standards on Functional Safety Determining Risk Reduction at existing Turbo Machinery Summary Page 26 June 2014
27 Summary Retrofit of Turbine Protection Systems does not allow reduction of safety for Operation of Turbo Machinery Application of Functional Safety standards - state of the art approach for design of protection functions in Turbine Protection retrofit projects Safety Integrity Level determined based on VDMA standard 4315 reduces project specific effort Early determination of SIL requirements avoids additional project costs Highest reliability - use of SIL certified components only Page 27 June 2014
28 Thank you! Answers for energy.
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