industrial safety - gain · • pgs29 translation • tank types and level detection • state of...
TRANSCRIPT
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Products Solutions Services
High Level Alarms
Industrial Safety
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Erwin Post
Only a safe plant is economical
• Product Manager Level• Tankgauging• Praxis mit Gamma.
Endress+Hauser B.V. | Nikkelstraat 6 | 1411 AJ Naarden | The NetherlandsPhone: +31 35 6958 710 | Mobile: +31 6 51836 366 | Fax: +31 35 6954 [email protected] | www.nl.endress.com
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Topics
Only a safe plant is economical
Overfill prevention
• Bunchfield lessons learned• PGS29 translation• Tank types and level detection• State of the art SIL level technology
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The Buncefield facility
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Buncefield overspill incident
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Even visible from space
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Buncefield days after.
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And no casualties…(thank God it’s was Sunday)
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The Buncefield incident
• Fuel depot in Buncefield near London• Sunday morning, December 11th, 2005• Failure of level measurement, no change in level indication• High level alarm in override.• Overspill of 300m3 of gasoline.• Heavy explosion• 40 people injured• No fatal casualties• Depot and surroundings have been heavily damaged• Took several days before the fire was under control• Environmental emissions and damage.
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Products Solutions Services
High Level Alarms
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Lessons learned
Recommendation 3: Operators of Buncefield-type sites should protect against loss of containment of petrol and other highly flammable liquids by fitting a high integrity, automatic operating overfill prevention system (or a number of such systems, as appropriate) that is physically and electrically separate and independent from the tank gauging system.
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Lessons learned
Recommendation 5: All elements of an overfill prevention system should be proof tested in accordance with the validated arrangements and procedures sufficiently frequent to ensure the specified safety integrity level is maintained in practice in accordance with the requirements of Part 1 of BS EN 61511.
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Post Buncefield effect
• Oops, can that happen to us too?• Are the risk assessments OK? • Are the HAZOP studies done? • Did we cover all scenarios?• Authorities start to interfere• Regulations are improved or re-written (PGS 29)• Proof testing becomes mandatory! • What about SIL?
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SIL – Legal status
• Legal framework• Seveso Directive [„Seveso II“ - Directive 96/84/EC]• Workers protection regulations (social) • Environmental regulations• Associated permits or license system, local, regional or even national
• Regulations require “state of the art” equipment for safety assurance
• „State of the art” is defined in standards. i.e. for functional safety
• EN/IEC 61508 [EN August 2002] (generic standard)• EN/IEC 61511 [EN August 2004] (process industry
standard)
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PGS29:2008, 84 pages.
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PGS29:2008, 84 pages.
6.3.6 Hoogniveau-alarmering en overvulbeveiliging
87. Tanks moeten zijn uitgevoerd met:
a. een hoogniveau-alarmering die ter plaatse en / of in de controlekamer, alarm geeft, voordat het hoogst toelaatbare vloeistofniveau in de tank wordt bereikt, zodat maatregelen genomen kunnen worden om de pompcapaciteit te verminderen of het verpompen te stoppen, en;
b. een fysiek onafhankelijke instrumentele overvulbeveiliging die bij het bereiken van het hoogst toelaatbare vloeistofniveau in de tank de toevoer naar de tank doet stoppen.
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PGS29:2008, 84 pages.
De betrouwbaarheid van de instrumentatie en beveiligingen moet in relatie staan tot het veiligheidsrisico. Erdient een methodiek gehanteerd te worden die de samenhangtussen de risico’s, vastgesteld middels veiligheidsstudies, en (de betrouwbaarheid van de) maatregelen (instrumentatie en beveiligingen) aantoont en documenteert.
Voorbeelden van methodieken:− SIL-systematiek waarin, afhankelijk van de gewensterisicoreductie, eisen worden gesteld aan dekeuze en onderhoudsfrequentie/type van de benodigderegelingen en beveiligingen; (NEN-EN 61511/61508)− safety-layerssystematiek, bijv. LOPA;− bedrijfsbeleid waarmee het risico gekoppeld wordt aan de maatregel; b.v. bij een scenario met risicowaardering X moeten minimaal twee onafhankelijke LOD’s (Lines Of Defense) worden ingezet om het risico te beheersen.
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PGS29:2008, 84 pages.
Toelichting:Indien bij scheepslossingen de tweede beveiliging technisch niet mogelijk is, kan in overleg met het bevoegd gezag hiervanafgezien worden of een alternatieve oplossing worden overeengekomen met een aanvaardbaar beschermingsniveau.
Onder fysiek onafhankelijk wordt verstaan:− Los van niveaumeting− Apart stuursignaal
Onder overvulbeveiliging wordt verstaan:− Elk systeem dat de toevoer tot de tank automatischdoet stoppen zonder tussenkomst van een operator.
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Simple instrument safety rules still apply
• A good High Level Alarm typically:• is based on a different physical phenomenon (avoid systematic
failures)• is “Fail to Safe” classified for SIL services• is active (needs power to operate)• is proven technology • has all appropriate certificates (IEC 61508/61511)• is provided with internal diagnostics• is preferably provided with a separate failure alarm• can be checked easily…………. Proof testing• has a long, predictable lifetime• can be repaired immediately without process interference
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Typical bulk liquid storage tanks
Fig. a. storage tank with conical roof Fig. b. storage tank with external floating roof
Possibilities are determined by tank constructions
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Fixed Roof – SAFE HHLA Solutions
Tuning Fork Measurement of aggregation phase by density, Gas versus Liquid
Radar and Guided Wave Radar.Measurement of true level using di-electric impedance jump at phase change
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Liquid Bulk Storage, Independent High Level Alarms
State of the art.• Liquiphant is always the first solution.
• SIL2/3 Compliant - IEC61508/IEC61511 – Loop approach!• Suitable for all Cone Roof Tanks using existing tank fittings.• Very simple and cost effective proof testing by push button only!
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Liquiphant summary
• Liquiphant is an active in-situ density measurement rather than a switch!
• Density change of liquids is huge and the absolute density of liquid phase is irrelevant thus providing a robust physical deviation.
• Easy test methodology using push button activated test generator• Simplicity of the concept offers extremely low failure rates. Availability
joined to the highest safety level!• Proven as robust. Reliable lifetime is typically long!
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Function Principle
filter / amplifier
phaseshift amplifier
evaluation electronic
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Self-Monitoring
sensoralarm
0,4 s delayed
400fa-15%
fafa+ 6,5%
1500 f [Hz]
25 mm
0
0
Immersion depth
corrosionalarm
60 s delayed
sensorAlarm
0,4 s delayed
normal operation
fa-15% switch point approx. 850 Hz
ALARM
ALARM
Safe alarm function
fa oscillation frequency in air approx. 1 kHz
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Recurring Proof Test of Overspill Protections
switc
hing
elec
tron
ic
receiver
switch
test generator
switch
pulse
switch relay
fault relay
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Push button proof test coverage (1)
Driv
e cu
rren
t
Reso
nanc
e fr
eque
ncy
Only the resonance
controller is not covered
λdu controller: 10 FIT [FIT = 10-9 · 1-h)
Frequency
λdu 40 FIT
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Push button proof test coverage (2)
0,000E+00
3,500E-04
7,000E-04
1,050E-03
1,400E-03
1,750E-03
2,100E-03
0 1 2 3 4 5 6 7 8 9 10
PFD
yr
Failure rate FTL5* and 7* series connected to FTL325P
PTC 75%
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Overview of measures“ for SIS according to IEC61511Component Level
Redundancy1oo1 • 1oo2 • 2oo2 • 2oo3
• Certified IEC61508 + „Prove in application“
or• Proven-in use [supplier]
or •Prior-use demonstration [user]
Systematic Failures
RandomFailures
&
FailureTolerance
&
∑PFDavg
• Certified IEC61508
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Fixed Roof – SAFE HHLA Solutions
Tuning Fork Measurement of aggregation phase by density, Gas versus Liquid
Radar and Guided Wave RadarMeasurement of true level using di-electric impedance jump at phase change
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Liquid Bulk Storage - Fixed Roof TanksGuided radar
• Suitable for all Cone Roof Tanks using existing tank fittings on tank.• Continuous level Measurement.• Flexible set points via 4-20mA Signal
• Deviation alarms possible (comparing with ATG)• Provided with internal redundancy using End Of Probe algorithm• SIL 2/3 Compliant - IEC61508• Safety parameters are state of the art.• Proof testing by generating test signals.
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Developed according IEC61508
Continuous automatic internal check in the device
• Logic program run control
• Reference pulse HF
• Quartz synchronization
• Measuring cycle time
• Supply voltage
• Temperature
• Check sum RAM
• Cable breakage
Check
• Continuous self-monitoring to check the correct functionality of the device • More than 80 diagnostic measures and techniques permanently running in the
background
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Proof test from control room
Proof procedure via manual started self check (proof test)
Send
Check
Developed acc. to IEC61508, also the data communication between Device-DTM and device is secured (send – check).
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HistoROM
Electronic change during night shift
The HistoROM isfixed in the housing(can not be lost or“forgotten”)
Example HistoROM functionality
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Floating Roof – Safe HHLA Solutions
(Tuning fork – Stilling well mounted is always preferred)
Free Field Radar, Time of FlightMeasurement of roof level using dielectric reflection at phase change
Capacitance type contact switchingMeasurement of dielectric impedance change by roof contact
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Floating Roof TanksFree Space Radar • Free Space Radar
• Suitable for all tank types (Excluding Spheres).• Continuous level Measurement.• Flexible set points via 2-wire 4-20mA Signal• SIL2/3 Compliant - IEC61508• Proof testing by test generator
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Floating Roof TanksFree Space Radar – Proof Testing external
External Swivel plate for
functional proof testing
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Floating Roof TanksRadar – Proof Testing integral design
• Complete with checker mechanism to enable safe alarm checks can be performed and ensuring Zone segregation.
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Developed according IEC61508
Continuous automatic internal check in the device
• Logic program run control
• Reference pulse HF
• Quartz synchronization
• Measuring cycle time
• Supply voltage
• Temperature
• Check sum RAM
• Cable breakage
Check
• Continuous self-monitoring to check the correct functionality of the device • More than 80 diagnostic measures and techniques permanently running in the
background
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Floating Roof – Safe HHLA Solutions
(Tuning fork – Stilling well mounted is always preferred)
Free Field Radar, Time of FlightMeasurement of roof level using dielectric reflection at phase change
Capacitance type contact switchingMeasurement of dielectric impedance change by roof contact
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Floating Roof Tanks (alternatively)Capacitance
• Capacitance Probe• Suitable for all Cone Roof Tanks using existing tank fittings on tank.• Suitable for Floating Decks.• Flexible set points via 4-20mA Signal, or via switch point.• SIL2 Compliant - IEC61508/IEC61511• Snow tolerant solution• Hard to test (mechanical
contact required)
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Secure Switch Settings using Contact Plate
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Floating roof failure scenariosDamaged deck
• May lead to lost and deflected echo depending on deck position• Fails Safe
• Switch level may raise depending on deck position• May fail when deck gets over flooded
Lost deck
• May lead to some switch point deviation (up to 100 mm)• No failure
• May lead to severe switch point deviation• Fails dangerous
• May become safe when weight is modified
Snow cover
• May lead to lost echo• Fails SafeAvailability increased
using new Advanced Dynamics design
• Top of snow detected as raised level
• No Failure
Free space Radar
Capacitancetype
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Summary
Only a safe plant is economical
Overfill prevention
• Bunchfield lessons learned• PGS29 translation• Tank types and level detection• State of the art SIL level technology
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Products Solutions Services
Thank you very much for your attention