安全仪表系统简介ppt课件

1、Introduction to E&I Safety Instrumented Systems (SIS)电仪安全仪表系统电仪安全仪表系统(SIS) 介绍介绍2019-04-28Ulrich Schuenemann BYC NanjingBYC 南京南京尤瑞奇尤瑞奇 舒曼舒曼CTA DepartmentE&I maintenance EOEG电仪维修电仪维修EOEG CTA部部lControl loops 控制回路 DCSl lMonitoring functions 检测功能DCSlInterlocks needed for smooth operation DCS, (ES

2、D) l 顺利运行所需的连锁lInterlocks related to plant Safety ESD与装置安全有关的连锁There are different E&I functions 电仪功能各不相同电仪功能各不相同What are E&I S.I.S. 什么是电仪什么是电仪S.I.S?E&I Safety Instrumented Systems (S.I.S.): E&I Safety Instrumented Systems (S.I.S.): 电仪安全仪表系统电仪安全仪表系统S.I.S. prevent S.I.S. prevent 安全仪表系

3、统用于防止：安全仪表系统用于防止：personnel injury personnel injury 人身伤害或人身伤害或 environmental damage environmental damage 环境破坏环境破坏caused by a not tolerable fault state of caused by a not tolerable fault state of the plant the plant 由装置的不可接受的故障所造成由装置的不可接受的故障所造成 S.I.S. are defined in the Safety Review S.I.S. are define

4、d in the Safety Review Step 2.Step 2. 安全仪表系统是在安全风险评估的第二步安全仪表系统是在安全风险评估的第二步中定义的中定义的Classification of E&I functions 电仪电仪功能的分类功能的分类Definition of SIS: Safety Review step 2SIS的定义的定义: 安全审查步骤安全审查步骤2 SEVERITY 严重性S1 Potential for one or more fatalitiesS2 Potential for one or more serious injuries (irreve

5、rsible)S3 Potential for one or more lost time injuriesS4 Potential for minor injuries, or irritationE&I SIS can be used for “risk class B and C”.电仪SIS可用于 “B级和C级风险”SeverityProbability严严重性概率重性概率S1S2S3S4P0 (=1/y)ABDEP1 (1/10y)A/BBEEP2 (1/100y)BCEFP3 (1/1.000y)CDFFP4 (1/10.000y)EFFFExample: E&I

6、Safety Review 2 Checklist实例实例: 电仪安全审查电仪安全审查2检查清单检查清单Failures of a S.I.S. S.I.S的故障的故障lActive errorltriggers off the safety function for no reasonlplant is switched back to safe operationlreduction of production availabilityl 有源故障有源故障l-无缘无故触发安全功能无缘无故触发安全功能l-装置切回到安全运行装置切回到安全运行l-生产运行可用率降低生产运行可用率降低lPassi

7、ve error 无源故障无源故障linhibits the required safety function lplant continues operation although it should be switched offlimpacting the process safetyadversely affecting the safety function 对安全功能产生不利影响对安全功能产生不利影响no adverse effect onthe safety function对安全功能无不利影响对安全功能无不利影响Failure 故障故障Time-averaged probabi

8、lity for a passive Time-averaged probability for a passive fault : fault : PFD “Probability of Failure on Demand” PFD “Probability of Failure on Demand” 无源故障的时间平均可能性无源故障的时间平均可能性: :PFDPFD指令故障的可能性指令故障的可能性“ “Components of a SIS SIS的组分的组分Shut-Down SystemShut-Down System 停车系统停车系统Logic in Failsafe Logic i

9、n Failsafe PLC or Hardwired PLC or Hardwired systemsystem在故障安全型可编程在故障安全型可编程控制器或硬接线系统控制器或硬接线系统中的逻辑中的逻辑Redundant sensors冗余的传感器Valve阀门Solenoid valve电磁阀Instrument air supply 仪表气源Rack Room Rack Room 机柜间机柜间Field Field 现场现场Passive Faults of sensors and actuators传感器和致动器的无源故障传感器和致动器的无源故障mass flow meter mass

10、flow meter after pressure after pressure pulsepulse压力脉冲下游的压力脉冲下游的质量流量计质量流量计lost control valve plugcontrol valve plug, damaged by cavitationrestriction orifice, deformed by flow限流孔板限流孔限流孔板限流孔板, 流量造成的变形流量造成的变形调节阀阀塞调节阀阀塞,空穴造成的损坏空穴造成的损坏Some mathematics 一些算法一些算法TITest Interval between functional tests of

11、 SIS,time needed to discover dangerous faults SIS功能测试之间的时间间隔, 发现危险故障需要的时间MTBFMean Time Between Failure of an equipment 设备故障之间的平均时间l = 1/ MTBFfailure rate 故障率Pf (t)Probability of failure (to function). For constantfailure rates l :Pf (t) = (1 e-l t ) 故障概率(对功能而言).恒定故障率 l : Pf (t) = (1 e-l t ) PFDProba

12、bility of Failure on Demand= Pf (t) , time averaged over test interval TI 指令故障概率= Pf (t) , 时间间隔TI的平均时间 PFD = 1/TI 0TI Pf (t) dtPFD Probability of Failure on DemandPFD指令故障概率指令故障概率 Probability Pf(t) for finding equipment in dangerous fault state after time t has passed since last functional test自上次功能试

13、验以来经过时间 t 后 ,发现设备处在危险故障状态的概率.Pf (t) = (1 e-l t ) time average 时间平均值PFD Probability of Failure on demandPFD指令故障概率PFD depends on failure rate of equipment AND test interval.PFD取决于设备AND试验间隔的故障率Calculation of PFD PFD的计算的计算lPFD calculation of an individual equipment easy, if you haveltest interval lfailu

14、re rate (given by supplier)l如有试验间隔和故障率(供货方提供), 则某个设备的PFD计算就不难lPFD-calculation for more complex configurations (2oo3 etc. ) can be done using simple statistical models: Good for comparing different configurations.用简单的统计模型可进行较复杂的配置(2019等)的PFD计算lFor SIS: PFD of field domain and control domain must be a

15、dded.l 对于SIS: 必须加上磁场域和控制域的PFDl PFDSIS = PFDsensor + PFDPLC + PFDactuator Calculation of PFD the problemsPFD的计算的计算问题问题PFD data for field instruments usually not very reliable(not experimentally verified for chemical environment). 用于现场仪表的PFD数据通常不是很可靠(对于化学环境未经试验验证).Contribution to Failure Probability (

16、PFD):对故障概率的影响因素calculated values for PFD: often not very accurate. PFD计算值: 经常不太准Field InstrumentsField Instruments85 % 85 % 现场仪表现场仪表Logic SolverLogic Solver(failsafe PLC)(failsafe PLC)15 %15 %逻辑解答器逻辑解答器( (故障保护故障保护PLC)PLC)“SIL” requirements for SIS SIS的的“SIL要求要求Safety Integrity Level(SIL)安全一体化水安全一体化水

17、平平Probability of Failure on Demand (PFD)指令故障概率指令故障概率1 0.10 - 0.01operating and monitoring functions 运行和检测功能运行和检测功能20.01 - 0.001SIS (“Class A functions”)SIS (“A级功能级功能”)30.001 - 0.0001For SIS: international and BASF standards request SIL 2 or SIL 3.对于SIS: 国际标准和巴斯夫标准要求SIL2 或 SIL3.How to meet “SIL” requ

18、irements 如何满足如何满足“SIL要求要求Right Instruments: from BASF standard list (field proven) or certified 仪表正确 : 来自巴斯夫标准清单或核准者 (SIL 2, TUV certificate,) Devices without systematic design or manufacturing errors which can lead to common failure of redundant channels at the same time. 2. Right Design: Redundanc

19、y, Diversity. Use design typicals in BASF standard. 设计正确: 冗余, 多样性. 采用巴斯夫标准中的典型设计 Redundant (and diverse) channels of sensors and actuators make system tolerant against single passive and active faults. 3. Testing, Maintenance : perform commissioning test and periodic functional proof tests of SIS. 测

20、试,维护: 进行SIS调试试验和定期的功能验证试验 In order to discover passive faults of SIS. Test interval depends on design. BASF Global Standard Lists 巴斯巴斯夫全球标准清单夫全球标准清单BASFs Standard DevicesBASFs Standard Deviceshave passed extensive laboratory have passed extensive laboratory testing acc. to IEC770 at BASF, testing ac

21、c. to IEC770 at BASF, Ludwigshafen.Ludwigshafen.are field-proven in non-safety related are field-proven in non-safety related applications.applications.have shown no passive fault during field have shown no passive fault during field testing (at least 10 devices monitored testing (at least 10 device

22、s monitored for 1 year).for 1 year).巴斯夫的标准装置巴斯夫的标准装置已通过广泛的实验室试验已通过广泛的实验室试验, ,符合路德维希符合路德维希港巴斯夫港巴斯夫IEC770IEC770标准标准. .在相关危险应用中经过现场验证在相关危险应用中经过现场验证. .在现场测试中未出现无源故障在现场测试中未出现无源故障 ( (至少至少1010台台装置被检测了一年装置被检测了一年). ).Design: Typicals for SIL2 and SIL3 设计设计: SIL2 和和 SIL3的典型之处的典型之处SIL2:single channel design 1o

23、o1can be used12 month test interval可使用单信道设计可使用单信道设计1oo112个月的试验间隔个月的试验间隔SIL3:SIL3:single channel design not allowed single channel design not allowed at least: 2 sensors (1oo2) and 2 at least: 2 sensors (1oo2) and 2 actuators.actuators.12 month test interval.12 month test interval.不允许单信道设计不允许单信道设计至少至

24、少2 2个传感器个传感器(1oo2)(1oo2)和和2 2个致动器个致动器1212个月的试验间隔个月的试验间隔PFD of different Architectures 不同不同结构的结构的PFDWhats the best configuration: 1oo1, 1oo2, 2oo2, 2oo3, 2oo4, ?最佳组态是什么?Consider: “failure on demand”-rate (affects plant safety) “false trip”-rate (affects plant availability)须考虑: “指令故障率 (影响装置安全) “误跳闸率 (

25、影响装置可用率)2oo22oo2 / 2oo41oo12oo31oo31oo2 / 2oo42oo31oo31oo21oo1Commissioning & Proof Testing of E&I S.I.S.安全仪表系统的调试及试验安全仪表系统的调试及试验 All International and BASF standards for SIS require a All International and BASF standards for SIS require a documented testsdocumented tests所有有关的国际标准或所有有关的国际标准或

26、BASFBASF标准均要求对安全仪表系统进行有文档标准均要求对安全仪表系统进行有文档记录的测试记录的测试periodic proof tests periodic proof tests 周期性的试验周期性的试验commissioning test before startup commissioning test before startup 开车前的调试开车前的调试 Objective for Commissioning Test: Objective for Commissioning Test: 调试的目的是为了检查：调试的目的是为了检查：design according to Saf

27、ety Review 2 design according to Safety Review 2 设计遵照安全风险评估第二步所要求设计遵照安全风险评估第二步所要求installation ok installation ok 安装正确安装正确parameter settings ok parameter settings ok 参数设置无误参数设置无误function of instruments (sensors and actuators) ok function of instruments (sensors and actuators) ok 仪表功能传感器仪表功能传感器, ,执行器均

28、正确无误执行器均正确无误logic action correct logic action correct 逻辑动作正确逻辑动作正确Commissioning test of S.I.S. will be main task for CTA PM during Commissioning test of S.I.S. will be main task for CTA PM during commissioning of missioning of plants.在装置调试期间，安全仪表系统的调试是电仪经理的主要任务在装置调试期间，安全仪表系统的调试是电仪经理的主要任务Responsibilities 职责职责CTA manager CTACTA经理经理Plant Manager装置经装置经理理Project team项目项目组组prepare prepare procedures procedures for for commission