安全连锁控制解决方法

1、The industries CPCIA中国石油和化学工业协会中国石油和化学工业协会 王如君王如君Refining炼油厂炼油厂OFF-SHORE PLATFORMS 海上平台海上平台ONSHORE GAS/OIL FIELDS油气储存油气储存Transportation传输传输Chemicals化工化工Transportation传输传输Marketing市场市场安全连锁控制 解决方案The industriesProduction产品产品Refining炼油厂炼油厂OFF-SHORE PLATFORMS 海上平台海上平台ONSHORE GAS/OIL FIELDS油气储存油气储存Transp

2、ortation传输传输Chemicals化工化工Transportation传输传输Marketing市场市场Where Are The Risks And Dangers In Your PlantDevelopment of Safety Solutions ConceptA history of accidents prompted legislation to improve safety, emergency planning, and public notification.OSHA, IEC61508, ISA84.01.ESD, F&G, BMS.大量的历史事故促使人

3、们立法大量的历史事故促使人们立法.OSHA, IEC61508, ISA84.01.ESD, F&G, BMS.以提高安全以提高安全,紧紧 急计急计划划,和公众的关注和公众的关注.Where Are The Risks And Dangers In Your PlantHistory of accidentsSource: J&H Marsh & McLennan, Inc.TYPES OF LOSSES损失种类0%10%20%30%40%Vapor CloudExplosionsFires ExplosionsOtherPercent of Losses损失百分比损失

4、百分比Where Are The Risks And Dangers In Your PlantDOLLAR LOSS BY TYPE OF FACILITY各种设备的经济损失0255075100125RefineryChemicalTerminalGas PlantMiscellaneousMillions of DollarsHistory of accidentsSource: J&H Marsh & McLennan, Inc.Where Are The Risks And Dangers In Your PlantHistory of accidentsCAUSES

5、OF LOSSESCAUSES OF LOSSES损失原因0%20%40%60%Mechanical FailureOperational ErrorUnknownProcess UpsetNatural HazardDesign ErrorSabotage/ArsonSource: J&H Marsh & McLennan, Inc.Percent of Losses损失的比例损失的比例Where Are The Risks And Dangers In Your PlantHistory of accidentsSource: J&H Marsh & McL

6、ennan, Inc.EQUIPMENT INVOLVED EQUIPMENT INVOLVED设备损失百分比 0%10%20%30%40%Piping SystemsTanksReactorsProcess TowersPump/CompressorProcess DrumsMiscellaneousUnknownHeat ExchangersMarine VesselHeaters/BoilersPercent of LossesWhere Are The Risks And Dangers In Your PlantRoot Cause from Safety IncidentsSpec

7、ification技术规范要求技术规范要求43%Design & Implementation设计及实施设计及实施15%Installation & Commissioning安装及调试安装及调试6% Operation & Maintenance操作及维护操作及维护15%Changes after Commissioning运行后的变化运行后的变化21%Note: Based on 34 investigated incidents in the UK: “Out of Control”, HSE根据英国安全健康委员会对根据英国安全健康委员会对34件事故的调查结果件事

8、故的调查结果Where Are The Risks And Dangers In Your PlantHistory - Mexico City, Mexico, 1984nLPG explosion caused by leak at a marketing terminal pipeline that ignited and started a fire at the terminal LPG 的爆炸由管线终端的泄漏导致的大火引起的的爆炸由管线终端的泄漏导致的大火引起的nNumerous BLEVEs (Boiling Liquid Expanding Vapor Explosions)数

9、以万计的数以万计的BLEVE (沸腾的液体膨胀气体爆炸沸腾的液体膨胀气体爆炸)nOver 650 fatalities, most of which were in the neighboring communities650人遇难人遇难Where Are The Risks And Dangers In Your PlantHistory - Mexico City, Mexico, 1984History - Mexico City, Mexico, 1984History - Mexico City, Mexico, 1984History - Mexico City, Mexico,

10、1984History - Bhopal, India, 1984 在印度发生的事故在印度发生的事故nPesticide plant owned by Union Carbide 联合炭化物的一个杀虫剂厂联合炭化物的一个杀虫剂厂nMethyl isocyanate release from an interim storage tank following water ingress to the tank 甲异氰酸盐伴随着水从一个临时的储存罐释放到另甲异氰酸盐伴随着水从一个临时的储存罐释放到另一个大罐一个大罐nThe scrubber and flare system were inoper

11、ative 清洁和排泄系统不起作用清洁和排泄系统不起作用(无效无效)nOver 3800 fatalities in the community 超过超过3,800人不幸遭遇这起事故人不幸遭遇这起事故Where Are The Risks And Dangers In Your PlantHistory - Bhopal MIC FacilityHistory - Bhopal - AftermathHistory - Phillips Petroleum, Pasadena, Texas, 1989nPetrochemical plant (ethylene) 石化厂石化厂(乙烯乙烯)nA

12、seal blew out on an ethylene loop reactor, releasing ethylene-isobutane, a compound used in making plastics 乙烯厂的一个循环反应器释放出乙烯乙烯厂的一个循环反应器释放出乙烯-异丁烷异丁烷,一种一种用来制造塑料的混合物用来制造塑料的混合物,由于封条由于封条/密封爆裂造成密封爆裂造成nA massive unconfined vapor cloud explosion and fire resulted 大量的泄漏物爆炸导致火灾大量的泄漏物爆炸导致火灾n23 fatalities many

13、in the control room 23人遇难人遇难-许多是在控制室中许多是在控制室中nDeficient contractor safety guidelines (unaware of the design of the valve on the reactor and unsupervised as they made live repairs由于反应器检修无法得知其设计值也无法进行监督由于反应器检修无法得知其设计值也无法进行监督Where Are The Risks And Dangers In Your PlantHistory - Phillips Petroleum, Pas

14、adena, Texas, 1989History - Phillips Petroleum, Pasadena, Texas, 1989History - Pemex, 1996Oil & Gas Journal, November 25, 1996Pemex under fire after tank farm blast墨西哥石油公司罐区发生爆炸之后引起火灾墨西哥石油公司罐区发生爆炸之后引起火灾A faulty, outdated valve apparently caused the huge blast有一个过期的阀门故障引起爆炸有一个过期的阀门故障引起爆炸November

15、11 at a gasoline tank farml 4 workers killed, 19 injured 死亡死亡4人，伤人，伤19人人l $5M Product Loss 5百万产品损失百万产品损失l Two Storage Tanks Destroyed 2储存罐被摧毁储存罐被摧毁l 5,000 People Evacuated 5,000人被迫撤离人被迫撤离Where Are The Risks And Dangers In Your PlantHistory - ThaiOil - Oil Storage Tank FireWhere Are The Risks And Dan

16、gers In Your PlantHistory - ThaiOil - Oil Storage Tank FirelThai Lube/Oil Refinery, Thailand 泰国润滑油炼厂泰国润滑油炼厂l11:30 pm Thursday, 12-02-1999lOverfill of gasoline storage tank储存罐中存有过量储存罐中存有过量汽油汽油lSecurity guard detected a strong smell and notified shift control who sent two operators to investigate by d

17、riving a truck to the area. 保安察觉到强烈的汽油味保安察觉到强烈的汽油味,并通知并通知2位操作员驱车前往位操作员驱车前往对储存罐进行检查对储存罐进行检查lThe fire spread from one tank to 4 others before it was contained 火势失控从火势失控从1个罐烧向其它个罐烧向其它4个个lThe fire eventually was allowed to completely burn out since they could not fight this size of fire火势最终失去控制火势最终失去控制l

18、Over 100,000 liters were involved. 损失超过损失超过100,000升升Where Are The Risks And Dangers In Your PlantHistory - ThaiOil - Oil Storage Tank FirelThere were 8 fatalities and 13 hospitalized with serious injuries 8人遇难人遇难,13受伤受伤lWould have been significantly worse if it had occurred during the day as the dea

19、th toll would have been easily over 100 一天伤亡近一天伤亡近100人的代价和后果是十分惨重的人的代价和后果是十分惨重的lDamaged facilities损失的设备损失的设备:n5 tanks 5个罐个罐nadmin building 行政楼行政楼nmaintenance workshop 维护车间维护车间nstore 商店商店nmedical center 医疗中心医疗中心nengineering office 工程部工程部nfire station with 3 fire trucks (which is right next door to th

20、e tank farm)Where Are The Risks And Dangers In Your PlantHistory - ThaiOil - Oil Storage Tank FirelThey were in the process of bringing units back on stream after a 6 week shutdown due to poor economics when the disaster occurred由于当时的经济不景气由于当时的经济不景气,事故发生之后事故发生之后,经过经过6个星期的停车才个星期的停车才恢复生产恢复生产lAll refin

21、ery process units had to be shutdown所有炼油厂过程控制设备不得不停车所有炼油厂过程控制设备不得不停车lAll the utility lines that come from Thai Oil Refinery run adjacent to where the fire occurred and are significantly damaged and extensive replacements needed to be done.所有从泰润滑油厂延伸出的管线和邻近事故现场的管线损失所有从泰润滑油厂延伸出的管线和邻近事故现场的管线损失严重严重,不得不进

22、行大范围的更换不得不进行大范围的更换lThai Lube was not be able to start up again until these repairs are completed (1 month)泰润滑油厂在泰润滑油厂在1个才重新开始运行个才重新开始运行Where Are The Risks And Dangers In Your PlantHistory - ThaiOil - Tank Overfill and FireHistory - ThaiOil - Tank Overfill and FireFatality From Explosionat Oil Storag

23、e TankMajor ReleaseFrom TankPersonnel inthe AreaIgnitionSourceLineLeakTankRuptureTankLeakTankOverfillPump LeftUnattendedFailure of LevelControl SystemTrainingInadequateToo ManyTasksHistory - ThaiOil - Tank Overfill Logic DiagramWhere Are The Risks And Dangers In Your PlantHistory - ThaiOil - Tank Ov

24、erfill AnalysisCausesConsequencesSLRRExisting SafeguardsRecommendationsRespPri1. Operator error in filling tank - Pump left on too long1.1. Tank overfill; possible fire if source of ignition is present; potential explosion if delayed ignition; possible explosion overpressure damage to the adjacent b

25、uildings and potential injury to workers133 1.1. High level alarm1. Provide additional training to the operators since the procedure to stay with the pump is not being followed routinely11.2. Operating procedure to remain with the pump during filling operation and to observe the level gauge2. Review

26、 the demands on the operator during pump filling since too many tasks is contributing to the risk of overfill since they cannot stay with the pump all the time and conduct their duties12. Level alarm high fails during loading and operator is not observing the filling operation2.1. Tank overfill; pos

27、sible fire if source of ignition is present; potential explosion if delayed ignition; possible explosion overpressure damage to the adjacent buildings and potential injury to workers144 2.1. Operating procedure to remain with the pump during filling operation and to observe the level gauge3. Review

28、the reliability of the level alarm system on T-0012Where Are The Risks And Dangers In Your PlantHistory - Kuwait Petroleum Corp Refinery Explosion 6-25-00lAn explosion caused by a gas leak from a line failure at Kuwaits Mina Al-Ahmadi refinery在科威特一家炼油厂在科威特一家炼油厂,由于管道破裂引起气体泄漏造成爆由于管道破裂引起气体泄漏造成爆炸炸lFour

29、fatalities and injured 49 others, according to the Kuwaiti News Agency.科威特新闻报道科威特新闻报道,有有4人遇难人遇难,49人受伤人受伤lSome units at the refinery would be out of operation for months and others for several weeks. 炼油厂的有些炼油厂的有些装置停止运作几个月装置停止运作几个月,有的停止几星期有的停止几星期lTwo 18,000 b/d gasoline units were severely damaged by

30、the explosion and fire. 爆炸和大火给两个爆炸和大火给两个18,000桶桶/天天生产能力的装置造成严重损失生产能力的装置造成严重损失lA 122,000 b/d crude unit suffered major damage, while a 120,000 b/d crude unit suffered moderate damage 一一个个122,000桶桶/天生产装置遭受重大损失天生产装置遭受重大损失Where Are The Risks And Dangers In Your PlantHistory - Kuwait Petroleum Corp Refin

31、ery Explosion 6-25-00History - Kuwait Petroleum Corp Refinery Explosion 6-25-00History - Kuwait Petroleum Corp Refinery Explosion 6-25-00History - Kuwait Petroleum Corp Refinery Explosion 6-25-00History - Kuwait Petroleum Corp Refinery Explosion 6-25-0028 years of safety lessons learnedSAFETY SOLUTI

32、ONIS MANDATORY FOR CRITICAL PROCESSThis could have been avoided.only if如果如果这是可以避免的这是可以避免的People人员人员 40%Equipment设备设备 40%Process 生产控制生产控制20% Minimal understanding of sources/impact 对资源对资源/效果的最低限的理解效果的最低限的理解 Lack of human-system integration 缺少人员缺少人员-系统集成系统集成 Tendency to design for normal situations 正常

33、情况的设计趋势正常情况的设计趋势 Skeletal engineering/technical support 工程工程/技术支持框架技术支持框架 Inadequate training methods 培训方法的不足培训方法的不足Some Critical Issues:Major Hazards - contributing factorsWhere Are The Risks And Dangers In Your PlantMajor Hazards - contributing factorslMaterials 材料材料nToxicity (Lethal Dose50, TLV,

34、STEL, .) 毒性毒性nFlammability (flash point, auto-ignition, flammability limits) 可燃性可燃性(闪光电，自动点火器，可燃性闪光电，自动点火器，可燃性)nExplosion (detonation, deflagration, VCE, BLEVE) 易燃易燃(爆裂，爆燃过程，爆裂，爆燃过程，VCE，BLEVE)lIgnition Sources 点燃火源点燃火源nElectrical equipment, static 电子设备，静电电子设备，静电nProcess flames 生产过程火焰生产过程火焰nFriction,

35、 matches, hot surfaces摩擦力，火柴，热表面摩擦力，火柴，热表面nReactive materials 电抗性材料电抗性材料lOperating deviations 生产过程中的偏差生产过程中的偏差nProcess variables (Temp, Flow, Pressure, Comp, ) 过程变量过程变量( 温度，流量，压力温度，流量，压力.)nTime or sequence 时间或顺序时间或顺序nHuman error 人为错误人为错误Where Are The Risks And Dangers In Your PlantAccepable Risks in

36、 .Acceptable risks vary from one country to another.Where Are The Risks And Dangers In Your PlantThe Cost of SafetyLost Production Opportunity (LPO) and Cost of Spurious Tripswith Relay-based or General Purpose PLC-based Safety Systems采用继电器或通用采用继电器或通用PLC作为安全系统所造成的停产损失作为安全系统所造成的停产损失Unit生产单元生产单元Unit S

37、ize装置规模装置规模Cost andLPO ofSpuriousTripNumber ofSpuriousTrips peryearTotal Costper yearCrude Unit180 K BPD$540K1$540KFCCU60 K BPD$375K1$375KHydrotreater30 K BPD$53K1$53KCCR30 K BPD$150K1$150KHydrocracker45 K BPD$125K1$125KMajor IncidentN/a$1,500K.5$750KTotal Annual Cost $1,993KWhere Are The Risks And

38、Dangers In Your PlantSource: API report “1999 Safety Performance Measurements”据API消息Costs per Incident (US$)Number of IncidentsAverage (US$)Total Cost (US$)5M215,000,000$ 30,000,000$ No Cost Given41,000,000$ 4,000,000$ 8563,587,500$ The Cost of SafetySafety Incidents (not including Fines and Lawsuit

39、s) average $1.7M per year for a 200K bbls refinery (source API)安全事故安全事故(不包括罚款和被指控不包括罚款和被指控)事件平均每事件平均每年每年每200K桶油造成的损失达桶油造成的损失达170万美元万美元 Where Are The Risks And Dangers In Your PlantThe Cost of SafetylSafety Incident 安全事件安全事件: nWhere the Safety System failed to properly bring the process to a safe sta

40、te when required to, due to a covert (or unknown) failure of the Safety System. 对安全系统的要求是无论发生明显或不明显的故障对安全系统的要求是无论发生明显或不明显的故障,安全系统必须将生产安全系统必须将生产过程带入安全状态过程带入安全状态.lMinor Safety Incident小事件小事件: nAdditional Layers of Protection (such as relief valves) were functional and provided some level protection.额外

41、的保护层提供一些额外的保护层提供一些保护保护(例如解放阀例如解放阀)nTypical cost $350K to $500K per incident每个事件的成本为美金每个事件的成本为美金350K至美金至美金500K.lMajor Incident重大事件重大事件:nAdditional Layers of Protection were either not functional or available.额外的保护层没有发挥作用或者根本不存在额外的保护层没有发挥作用或者根本不存在nTypical cost $2,500K to $5,000K per incident. 每个事件的成本为

42、美金每个事件的成本为美金2,500K至美金至美金5,000K. Where Are The Risks And Dangers In Your PlantSocial Responsibility“AT THE HEART OF OUR CORPORATE CULTURE AR FOUR CORE VALUES - SAFETY AND HEALTH, ENVIRONMENTAL STEWARDSHIP, VALUING ALL PEOPLE AND BUSINESS ETHICS.” Conoco 1999 Annual Report“SAFE, RELIABLE, EFFICIENT OP

43、ERATIONS COMPANY WIDE ARE ESSENTIAL TO ACHIEVING OUR OBJECTIVES. THIS IS JOB NO. 1 FOR ALL OF US DAY IN AND DAY. WE ARE COMMITTED TO ENSURING CONTINUED AND SUSTAINABLE IMPROVEMENTS IN OUR OPERATIONS.” Chevron 1999 Annual Report“WE PLEDGE TO BE A GOOD CORPORATE CITIZEN IN ALL PLACES WE OPERATE WORLDW

44、IDE. WE WILL MAINTAIN THE HIGHEST ETHICAL STANDARDS, OBEY ALL APPLICABLE LAWS AND REGULATIONS, AND RESPECT LOCAL AND NATIONAL CULTURES. ABOVE ALL OTHER OBJECTIVES, WE ARE DEDICATED TO RUNNING SAFE AND ENVIRONMENTALLY REPONSIBLE OPERATIONS.”ExxonMobil Corporate Overview “Guiding Principles” June 2000

45、Where Are The Risks And Dangers In Your PlantAvoid Risks And Dangers In Your Plant By Applying Safety StandardDefinition of a Safety System 安全系统的定义安全系统的定义Safety systems are designed to respond to conditions of the plant, which may be hazardous in themselves, or if no action were taken could eventual

46、ly give rise to a hazard. They must generate the correct outputs to prevent the hazard or mitigate the consequences.安全系统应设计为在工厂发生紧急情况下安全系统应设计为在工厂发生紧急情况下,或系统本身发或系统本身发生故障的情况下生故障的情况下,必须作出及时的反应必须作出及时的反应,而且是产生一个而且是产生一个正确的反应输出到现场正确的反应输出到现场,以防止任何危险发生或减轻后果以防止任何危险发生或减轻后果. 如果系统没有反应将最终导致或加重危险的后果如果系统没有反应将最终导致或加

47、重危险的后果.Avoid Risks And Dangers In Your Plant By Applying Safety StandardSome common names used for Safety System :安全系统的常用名称安全系统的常用名称 :nESD Emergency Shutdown System 紧急停车系统紧急停车系统 nSIS Shutdown Interlock / Instrument System停车连锁停车连锁/仪表系统仪表系统nBMS Burner Management System 燃烧器管理系统燃烧器管理系统nF&G Fire &

48、; Gas Protective System火和气保护系统火和气保护系统nIPS Instrument Protective System 仪表保护系统仪表保护系统Definition of a Safety System 安全系统的定义安全系统的定义Safety System Applications安全系统应用范围Avoid Risks And Dangers In Your Plant By Applying Safety Standard Boiler / Burner Management Systems锅炉锅炉/燃烧管理系统燃烧管理系统 Continuous Production

49、 Units - Refining and Petrochemical Process 连续性生产过程连续性生产过程-炼油厂和石油化工厂炼油厂和石油化工厂 Batch Processes 批量生产过程批量生产过程 On- and Offshore Oil & Gas Exploration and Production Facilities 岸上岸上/海上油海上油/气体勘探和生产设备气体勘探和生产设备 Compressor & turbine Monitoring / Safeguard 压缩机和透平压缩机和透平机监视机监视/防护防护 Fire & Gas Detect

50、ion 火和气体监测火和气体监测 Loading and Storage Facilities 装载装载/储存设备储存设备 Pipeline Safety Management Systems 管道安全管理系统管道安全管理系统The International Safety Standards - Safety Compliance Avoid Risks And Dangers In Your Plant By Applying Safety StandardlANSI/ISA S84.01; Application of safety instrumented systems for th

51、e process industries, 1996lIEC61508 (and dS61511); Functional safety - safety related systems, 1998-2000lAPI RP14C; Analysis, design, installation, and testing of basic surface safety systems for offshore production platformslFM 7605; Programmable logic control based burner management systemlDIN1925

52、0; Fundamental aspects to be considered for measurement and control equipment.lDIN0116; Electrical equipment of furnaces safety related requirements of electronic components.lNFPA 8502 & 85C; Prevention of furnace explosions/implosions in multiple burner boilersSome important Standards, Guidelin

53、es, Practices.国际安全标准国际安全标准Avoid Risks And Dangers In Your Plant By Applying Safety Standardl“S84.01 is a national consensus standard”l“OSHA considers S84.01 to be recognized and generally accepted good engineering practice for SIS.”l“Per 1910.119(f)(1)(iv) the employer is required to develop and imp

54、lement written operating procedures involving safety systems.”l“If an employer documents per 1910.119(d)(3)(I)(F) that it will comply with S84.01 for SIS and it meets all S84.01requirements, the employer will be considered in compliance with OSHA PSM requirements for SIS”OSHA stated that, when imple

55、menting SISs in processes that are not covered by PSM, the user could be found in violation of the General Duty Clause of the OSHA Act, if an incident occurs and the SISs are determined to not conform with S84. The question most often asked is, What does it take to be compliant with S84?” After all,

56、 S84 was developed as a consensus standard covering a wide range of chemical processing. Compliance should be viewed as a three-step process: Decide how much risk reduction is required Design systems that can meet the risk reduction Operate, maintain and test the systems to ensure long-term risk red

57、uctionAvoid Risks And Dangers In Your Plant By Applying Safety StandardSome Safety Concept extracts安全概念摘要安全概念摘要Some Safety Concept extracts.OSHA 1910.119 - “The employer shall document that equipment complies with recognized and generally accepted good engineering practices.”ISA-S84, 2.1.3 - “The te

58、chniques and measures included in normative Clauses 1 through 11 are considered good engineering practices in design and support of Safety Instrument Systems.”ISA-S84, 7.2.11 (& OSHA 1910.119) - “Any detected single fault that causes an SIS failure shall result in an automatic, predetermined, sa

59、fe failure action.”ISA-S84, 7.3.3 - “PES logic solvers shall have methods (internal and/or external) to protect against covert faults.”ISA-S84, 7.3.4 - “The logic solver shall be separated from the Basic Process Control System (BPCS).”NFPA 8502, 4.3.1 - “The logic system for burner management shall

60、be designed specifically so that a single failure in that system does not prevent an appropriate shutdown.”SIS concept - “Separation (Identical or Diverse), Redundancy (Identical or Diverse), Software design, Technology selections, Failure rates, Failures modes, Architecture, Power Sources, Common cause failures, Diagnostic requirements, Field devices, User interface, Security, Wiring