roxel solutions presentasjon teknologidag 2014
DESCRIPTION
TRANSCRIPT
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Teknologidag – 5 Juni 2014
New regulations for offshore rigs
Jan Forsell – Roxel Solutions AS
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My background:
Siemens O&G:- Responsible for F-systems, offshore- Eng manager, Eldfisk SAS upgrade- Eng manager, Statfjord Safety Systems
F&G, ESD, HIPPS, IOPS, OPPS- Project manager, Safety systems
Roxel Solutions AS:- General manager
Jan Forsell – Roxel Solutions AS
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Agenda:
• A minute about Roxel
• Short introduction to norms, standards and NPD rules
• SIL in Control System Projects – How to approach?– Rules and regulations– Project execution and verification– Programming tools– Equipment
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Roxel Group
• Revenue: 240 MNOK • Resources: 140• 13.400 m2
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Supplier of onshore and offshore solutions
LANDBASERT
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Drilling equipment packages
Independent system integration of 3’rd party suppliers
Product line:
• Drilling and utility systems• Cabins and LER• Instrumentation• EX equipment• Drives
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Mud & Cement – Integrated Solutions
MUD HANDLING SYSTEM
COMPLETE MUD & CEMENT SYSTEM
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References PSD EXPRO – Well Testing:
– 6 PSD SIL2 systems delivered– NORSOK – IEC61508/511/OLF070 – DNV– EX zone 1
Halliburton – Well Testing:– 1 PSD system, Under Balanced Drilling– 2 PSD systems, Well Testing
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New PSD system presentation Challenges:
High risk potentialHarsh environment Critical processPortable equipment
SAFETY SYSTEMS - Offshore
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Safety Systems - OffshoreSafetyIntegrityLevel
SIL4: Not used offshore (Nuclear power plants, train signalling systems)SIL3: Emergency/Critical systems (ESD/HIPPS)SIL2: Process and protection systems (PSD/F&G)SIL1: Lowest level, not used offshore
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Safety Instrumented Systems (SIS)
SafetyIntegrityLevel
SIL4: Not used offshore (Nuclear power plants, train signalling systems)SIL3: Emergency/Critical systems (ESD/HIPPS)SIL2: Process and protection systems (PSD/F&G)SIL1: Lowest level, not used offshore
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Safety Integrity Levels:
Focus on the complete system (Equipment Under Control)Mandatory risk evaluations – must be documented (SRS)Supplier must document that SIL is obtained
Focus on the complete lifecycle:
Design-Specification-Engineering-Testing-Operation-Demolition
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Standards for implementation offshore:
Ptil, Styringsforskrift §5 barriersPtil, Innretningsforskriften §8 safety functions
IEC61508 – Functional safety of control systems, framework, definition of SILIEC61511 – Engineering of safety systems for Process systemsOLF070 – NPD Guideline for minimum SIL levels on the NCS: - Define SIL levels, guidance on how to implement NPD demands
API RP 14C – Risk analysis, failure-mode-effects analysis (FMEA) and hazard-and-operability studies (HAZOPS), define risk levels and barriers, safe charts.
OLF070 specifies API RP 14C / ISO10418 (guideline for analysis, design, installation and testing of process safety systems)
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Connections between IEC norms:
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Standards for implementation for rigs:
DNV-OS-A101 – Safety Principles and Arrangements
Basic requirments for DNV verification, shutdown logic and alarms.
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Standards for implementation rigs:
DNV-OS-D202 – General requirements for safety and control systems: Design, fabrication, installation, testing, commissioning, operation, mainenance, re-qualification, and abandonment.
Availability class (R0) redundancy
Documentation,Ch3.1 Table B2
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NORSOKThe D series: Ongoing updates after Macondo incident:
D-002: Well Intervention, BOP SIL demand (also for well intervention)D-007: Well testing, mandatory SIL2 demand after july 2017
NORSOK points to OLF070 for minimum level.
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What must be adressed in a SIL project?
BeforeStartDuringAfter
- Government requirements- Customer demands- Internal requirement- Certifying body (DNV/ABS/…)
How to implement:- How to interpret Rules & Regulations- Failure Mode Effect Analysis (FMEA)- Hazard and operability studies (HAZOP)
- Documentation for SIL:Functional Design Specification (FS/FDS)Safety Requirement Specification (SRS)Safe Charts with Cause & EffectSIL loop definition
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What must be adressed in a SIL project?
BeforeStartDuringAfter
Interface Meeting:- How to interpret Rules & Regulations- How to document that SIL level is achieved- Responsibility interfaces
Technical (Instrumentation and loops)Formal meetingsContact with certifying body
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What must be adressed in a SIL project?
BeforeStartDuringAfter
Personnel qualification:
- Key personnel must be qualified and trained:- Project management- Lead engineers
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What must be adressed in a SIL project?
BeforeStartDuringAfter
Ensure that SIL is achieved:
- Project quality control- Documented traceability- Testing and verification- Documented conformity
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What must be adressed in a SIL project?
BeforeStartDuringAfter
Project quality control according to ISO9001:
• QA Plan with QA Activity List:- Technical Reviews (FDS/SW/HW/HMI)- Validation according to IAT/FAT procedures
• Safety Assessment and Validation Plan (SA&VP)- Identify and manage all safety aspects - How to verify and test (Nordtest Checklists)- How to implement IEC61508/511/OLF070- Change management (Risk&Impact analysis)
• Node Book:- All required design documents and reports
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What must be adressed in a SIL project?
BeforeStartDuringAfter
Installation and Commissioning:
• Procedures for - Storage and transportation- Installation - Commissioning - Testing
• Training:- Operator and Maintenance personnel
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What must be adressed in a SIL project?
BeforeStartDuringAfter
After delivery:
• SIL level must be maintained throughout the system lifetime:
- Documentation- Test intervals (instruments and control system)- Modifications and reconfiguration- Repair
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Roxel is approved as Solution Integrator by Siemens:
International program:1300 partners world wide7 partners in Norway
Roxel is approved for the following areas:
Process Control System SIMATIC PCS7, specializing on PCS 7 Safety Human Machine Interface SIMATIC HMI Automation System SIMATIC
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How the program works:
Support network- Siemens IADT in Oslo- Product experts in Germany
Competence through mandatory training- SIL courses in Germany (3 x 2 weeks)- Work shops- Partner Summits- Information on new products- Demo busses
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Siemens Safety Integrated
Why Siemens:
• Most common standard for O&G
• Largest portefolio of IEC61508 equipment
• Reliable and well proven
• Simatic expertise within Roxel
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Siemens Safety Integrated Safety according to IEC 61508/61511:
– Programming based on Siemens F-Tools:- Part of Simatic PCS 7 tools- Tested by TÜV
– Equipment based on SIMATIC Safety Integrated Systems (SIS):- S7-315F, single Fail-safe SIL2/3- ET200iSP combine SIL and Ex- F-SM I/O modules «Yellow series»
– Equipment based on SIMATIC PCS7:- S7-400F, single Fail-safe SIL2/3- Safety Matrix- ET200iSP combine SIL and Ex- F-SM I/O modules «Yellow series» Communication:- ProfiSAFE Single communication for Zone 1
Design review by 3rd party (Sintef, DnV, Scanpower…)
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Small systems
S7-300F:
• CPU: S7-315F mid-range SIL 3 w/ProfiSAFE DP• Integrated F-SM i/o-cards AI/DI/DO• Redundant power
Benefits:
+ Cheap hardware+ F-SM in one box AI/DI/DO+ Based on F-Library IEC1311 by TÜV+ Good for Small systems with low degree of changes
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PCS 7 systems
Technology:– Siemens S7-400 PLC
Software:– Siemens PCS 7– Safety Matrix
Benefits:+ Simplified programming+ More configuring+ Simplified documentation+ Close integration between logic and HMI+ Single or redundant+ Powerful
Drawbacks:÷ More expensive than S7-300, but cheaper in the long run…÷ Larger in size
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RIO units – Safe area Protection level IP20 Operating range 0...60°C (-20...60°C) Redundant connection (for H CPUs) I/O Module Redundancy (1 Sensor -> 2 Modules) Modularly expandable Max. 12 I/O modules per station I/O Modules with comprehensive diagnostics
Power supply Interface module for Profibus DPIM153-2
I/O moduleExpandablebackplane
Aluminium rail
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RIO units – Ex zone 2 or 1 - ET200iSP ET200iSP
– Specifications:- AC 85 … 264VAC- -20C … +70C - ATEX II 2 G (1)
Ex de [ia/ib] IIC T4
– Profibus DP:- Intrinsic safe communication Ex ib- Plug/unplug under Ex conditions- Single (or redundant) communication- Active EOL compensation
– Power supply- Ex d- Redundant power
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RIO units ET200iSP
– Possible housing:- EEx e for Zone 1 and 2- Wall mount- Stainless steel: DIN 1.4404 1.5 mm- Non-Corrosive materials- Expandable up to 32 modules
RS485-iS cables withBuccaneer
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Cause & Effect Requirements:
– Flexibility– Online verification– SIL demands
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Safety Matrix
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Benefits
The SIMATIC Safety Matrix as - Engineering Tool- Real time Viewer
Configuration of the Safety Functions with the Cause & Effects Method
Automatic TÜV-certified Creation of the Safety Logic from the Cause & Effect matrix
Easy Configuration without special Programming Knowledge
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Configuration, auto-generation and diagnostic tool for SIL3 application:
First-in alarm display and saving Integrated commands: bypass, reset, override, parameter modification Sequence of event display and savings Operator interventions Automatic version tracking Automatic documentation of modifications
Benefits
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HMI
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HMI
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HMIHMI Screens
Alarm Screen – YA711
Process Screens
Trending
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HART Interface
Simatic Process Device Manager HART Instrument Validation
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Agenda:• One minute about Roxel• Short introduction to Safety Integrity Levels - SIL• SIL in Programmable Electronic Systems (PES):
– Rules and regulations– Project execution and verification– Programming tools– Equipment
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PCS 7 systems
Technology:– Siemens S7-400 PLC
Software:– Siemens PCS 7– Safety Matrix
Benefits:– Less programming– More configuring– Simplified documentation
Drawbacks:– More expensive– Cheaper in the long run
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Documentation DNV-OS-D202 October 2008 - AUTOMATION, SAFETY, AND TELECOMMUNICATION SYSTEMS
– System Availability: R0 - Continuous available
– Certification and Classification requirements:
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Documentation
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DocumentationNODE Documentation according to Safety Validation and Assessment plan
Section 1, General:
Functional Specification, FS, FDS, (SRS and SAR)Node Plan and Progress Reports Revision recordCPI, Computer Point IndexC&E's, SCD's, SEQUENCE LOGIC/SFC'sSerial Links SpecificationsStatic Pictures Design BasisChange LogOther technical basis documents (MOM, TQ etc)Node software backup
Section 2, Hardware:
System Block DiagramGeneral Arrangement DrawingsPower Distribution DrawingsHardware Typicals Equipment Lists / SPIRInterface and Connection DrawingsX-Wiring and Circuit Diagrams
Secton 3, Test Dossier:
Test procedure (NORDTEST checklists)Certificates, Approvals and Statements.HW Test SheetsObject Test Report / Sheets Application Test ReportNode to node communication Test SheetsTest Reports for Test of Serial LinksPunch log
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DocumentationNORSOK Z-015:
1. Overall frame GA‘s.2. All junction box/enclosure GAs.3. Hydraulic Schematic Diagram if applicable.4. Electrical Schematic Diagram.5. Any Mimic Panel Drawings.6. System Block Diagram.7. Electrical Interconnection Diagrams and/or cable
schedules for all system/subsystems.8. Tubing Diagram if applicable.9. Operations Manuals for all system/subsystems.10. Maintenance Manuals for all system/subsystems.11. Recommended spares for all system/subsystems.12. Certification for all systems/subsystems including but not limited to:-
Hazardous area inspection schedule.Instructions for safe use.Special conditions of use.Any calculations to allow correct installation of
equipment in a hazardous area.Hazardous area equipment schedule.
13. EC declaration of conformity for all system/subsystems. (European directive).14. Interface Drawings.15. FAT/SIT procedures.16. Manufacturers and vendor test results for cabling used (IR and continuity).17. Manufacturers and vendor test results fibre cabling.18. All calculations and documentation pertaining to the achieved SIL rating.
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DocumentationNode book:
Documentation of relevant documents:
- Design documents and drawings- Specifications- Procedures- Change logs- Test reports
Purpose:
- System documentation- Conformity- Traceability
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DocumentationOther relevant activities:
- QA plan and QA activity list - Documentation review (Spec/C&E)- Technical reviews, HW, SW and HMI- Configuration Review- Participation in HAZID/HAZOP- Validation of procedures FAT/IAT- Internal Roxel procedures
- Experience transfer
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Instrumentation
Ea 8-23°
General:• All sensors SIL 2 (not Gamma), exd, exi
• Flow• Level• Temp.• Pressure• Mass
• Prosess Connection in SS316 (wet parts)• All type Signals incl.
• 4-20mA• Field bus (FF, PA, Hart)
• All sensors can be delivered w/options• Housing (ss 316)• Hasteloy c, titan, monel (wet parts)• Diagnostics tool kit
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Valves and actuators
General:• SIL 2, exd, exi, exm,
• Prosess Connection in brass, SS316 (wet parts)• Signals that can be provided
• 3-15 psi• 4-20mA• Field bus (PA, AS)• «most common supplies» (AC/DC)
• Can be delivered w/options• Housing (ss 316)• Hasteloy c, titan, monel (wet parts)