Valves and Solenoid Valves testet and certified byrheinhold & Mahla according to IEC 61508/61511

Transcription

1 Valves and Solenoid Valves testet and certified byrheinhold & Mahla according to IEC 61508/61511 Manfred Dietz SAMSON Dr. Thomas Karte Rheinhold & Mahla Industrieservice Höchst GmbH Business Unit MSR- und Analysentechnik

2 Contents History of Rheinhold and Mahla testlab Test center for fieldbus Test center for process automation devices SIL-loop influencing variables Safety contribution from user and manufacturer IEC SIL certified solenoid valves Proven in use at Hoechst AG valve series 3241/3251 Prior use the survey Results on valve survey Response to customer request Seite 2

3 Historyof Rheinhold & Mahla testlab The Rheinhold & Mahla testlab was founded by Hoechst AG in the year 1956 Since 1995 (diversification of Hoechst AG) the testlab was a part of the operating company Infraserv Höchst GmbH within the Industriepark Höchst 2003 the testlab, also the process analytics, maintenance and service stations were placed out into the Infraserv Höchst Technik GmbH 2005 the Infraserv Höchst Technik GmbH changed from Infraserv Höchst GmbH to Rheinhold & Mahla Seite 3

4 Competence Center for Fieldbus Center of Excellence Profibus Competence Center DTM Certification Center Seite 4

5 Type test for process automation devices SIL-test for manufaturer according TÜV regulations Diagnostic test according NE 107 Type test according NE 95 Seite 5

6 SIL-loop -Influencing variables- Hardware fault tolerance HFT PFD Design Failure rate SFF Diversity Beta-Faktor SIF Sensor SPS Aktor SIL PFD SFF Test intervall Proof test coverage Mean time to repair Maintenance Seite 6

7 Safety contribution from user and manifacturer User Manufacturer DIN V IEC VDI/VDE 2180 C1 C2 C3 C4 F1 F2 F1 F2 P1 P2 P1 P2 W3 W2 W no safety - requirements no special safety - requirements Risk - Area I SIL 1 ( lower risk ) SIL 2 Risk Area II SIL 3 ( higher risk ) Safe operation of Plant SIL 4 a SIS is not sufficient cannot be covered by SIS only Implementation of safety lifecycle -Risk analysis -Definition of safety loops -Implementation -Maintenance Reliability figures ( l SD,...,SFF) Source of figures Safety manual Seite 7

8 IEC SIL certified solenoid valves Test stand byr&m testlab SAMSOMATIC 3963 SAMSOMATIC 3964 SAMSOMATIC 3701 SAMSOMATIC 3756 SAMSOMATIC 3776 SAMSON 3730 integrated solenoid Seite 8

9 Proven in use at Hoechst AG-valve series 3241/3251 Former Hoechst AG, Frankfurt, Germany 100 production plants, people Variety of chemical processes valves at site, 3 5% safety functions Centralized engineering in past 1200 people Infraserv as inheritor of central engineering Industriepark Höchst Frankfurt Germany Seite 9

10 Prior use the survey Six years of investigation ( ) Based on total valve population of valves All valve complaints and repairs on area Hoechst AG were covered Guaranteed through central maintanance and workshop Forced by legislation (Gefahrgutverordnung) and internal company standard Special questionary for classification faults was developed Seite 10

11 Prior use the teststand Special training for personal at workshop in order to ensure consistent and reliable investigation and classification of faults Survey run by engingeering department of Hoechst, later Infraserv, always indepent from SAMSON A special decontamination room was operated in order to make investigations possible Seite 11

12 Results of valve survey Results for all valves (safety and control valves) Comprising valves and actuators MTBF generated by Infraserv Exida audit to generate failure rate and integrate Data into Silvertool Integration into other tools (Silence HIMA) pending Final result λ du = 5,46 8, no diagnostic coverage assumed Seite 12

13 Response to customer request Seite 13

14 Thanks for your attention You will find us in the Industriepark Höchst BU MSR- and Analysentechnik Building D Frankfurt am Main Tel.: