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1、Introduction to E&I Safety Instrumented Systems (SIS)电仪安全安全仪表系表系统(SIS) 介介绍2004-04-28Ulrich Schuenemann BYC NanjingBYC 南京南京尤瑞奇尤瑞奇 舒曼舒曼CTA DepartmentE&I maintenance EOEG电仪维修修EOEG CTA部部2004-04-28U.Schuenemann1CommissioningtestofE&ISISlControl loops 控制回路控制回路 DCS lMonitoring functions 检测功能检测功能DCSlInterlo
2、cks needed for smooth operation DCS, (ESD) 顺利运行所需的连锁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与装置安全有关的连锁There are different E&I functions 电仪功能各不相同功能各不相同2004-04-28U.Schuenemann2CommissioningtestofE&ISISWhat are E&I S.I.S. 什么是什么是电仪S.I.S?E&I Safety Instrumented Systems (S.I.S.):E&I Safe
3、ty Instrumented Systems (S.I.S.): 电仪安全仪表系统电仪安全仪表系统lS.I.S. preventS.I.S. prevent 安全仪表系统用于防止：安全仪表系统用于防止：personnel injurypersonnel injury 人身伤害或人身伤害或 environmental damageenvironmental damage 环境破坏环境破坏caused by a not tolerable fault state of the caused by a not tolerable fault state of the plant plant 由装置
4、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 lS.I.S. are defined in the Safety Review S.I.S. are defined 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中安全仪表系统是在安全风险评估的第二步中定义的定义的2004-04-28U.Schuenemann3CommissioningtestofE&ISISClassification of E&I functions 电仪功能的分功能的分类2004-04-28U.Schuenemann4Commissioningtesto
5、fE&ISISDefinition of SIS: Safety Review step 2SIS的定的定义: 安全安全审查步步骤2SEVERITY 严重性严重性S1PotentialforoneormorefatalitiesS2Potentialforoneormoreseriousinjuries(irreversible)S3PotentialforoneormorelosttimeinjuriesS4Potentialforminorinjuries,orirritationE&I SIS can be used for “risk class B and C”.电仪电仪SIS可用于
6、可用于 “B级和级和C级风险级风险”SeverityProbability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)EFFF2004-04-28U.Schuenemann5CommissioningtestofE&ISISExample: E&I Safety Review 2 Checklist实例例: 电仪安全安全审查2检查清清单2004-04-28U.Schuenemann6CommissioningtestofE&ISISFailures of
7、a S.I.S. S.I.S的故障的故障lActive errortriggers off the safety function for no reasonplant is switched back to safe operationreduction of production availability 有源故障有源故障-无无缘无故触无故触发安全功能安全功能-装置切回到安全运行装置切回到安全运行-生生产运行可用率降低运行可用率降低lPassive error 无源故障无源故障inhibits the required safety function plant continues ope
8、ration although it should be switched offimpacting 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-averagedprobabilityforapassivefault:PFD“ProbabilityofFailureonDemand”无源故障的时间平均可能性:PFD”指令故障的可能
9、性“2004-04-28U.Schuenemann7CommissioningtestofE&ISISComponents of a SIS SIS的的组分分Shut-Down SystemShut-Down System 停车系统停车系统Logic in Failsafe PLC or Hardwired system在故障安全型可编程控制器或硬接线系统中的逻辑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20
10、04-04-28U.Schuenemann8CommissioningtestofE&ISISPassive 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massflowmeterafterpressurepulse压力脉冲下游的质量流量计lostcontrolvalveplugcontrolvalveplug,damagedbycavitationrestrictionorifice,deformedbyflow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20
11、04-04-28U.Schuenemann9CommissioningtestofE&ISISSome mathematics 一些算法一些算法TITestIntervalbetweenfunctionaltestsofSIS,timeneededtodiscoverdangerousfaults SISSIS功能测试之间的时间间隔功能测试之间的时间间隔, , 发现危险故发现危险故障需要的时间障需要的时间MTBFMeanTimeBetweenFailureofanequipment设备故障之间的平均时间设备故障之间的平均时间l=1/MTBFfailurerate故障率故障率Pf(t)Proba
12、bilityoffailure(tofunction).Forconstantfailureratesl:Pf(t)=(1e-lt) 故障概率故障概率( (对功能而言对功能而言).).恒定故障率恒定故障率 l l : P : Pf f (t) = (1 e(t) = (1 e-l-l t t ) ) PFDProbabilityofFailureonDemand=Pf(t),timeaveragedovertestintervalTI指令故障概率指令故障概率= P= Pf f (t) , (t) , 时间间隔时间间隔TITI的平均的平均时间时间PFD=1/TI0TIPf(t)dt2004-04
13、-28U.Schuenemann10CommissioningtestofE&ISISPFD 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自上次功能自上次功能试验以以来来经过时间 t 后后 ,发现设备处在危在危险故障状故障状态的概的概率率.Pf(t)=(1e-lt)timeaverage时间平均值PFDProbabil
14、ityofFailureondemandPFDPFD指令故障概率指令故障概率PFDdependsonfailurerateofequipmentANDtestinterval.PFD取决于设备AND试验间隔的故障率2004-04-28U.Schuenemann11CommissioningtestofE&ISISCalculation of PFD PFD的的计算算lPFDcalculationofanindividualequipmenteasy,ifyouhavetestintervalfailurerate(givenbysupplier)如有如有试验间隔和故障率隔和故障率(供供货方提供
15、方提供), 则某个某个设备的的PFD计算就不算就不难lPFD-calculationformorecomplexconfigurations(2oo3etc.)canbedoneusingsimplestatisticalmodels:Goodforcomparingdifferentconfigurations.用用简单的的统计模型可模型可进行行较复复杂的配置的配置(2003等等)的的PFD计算算lForSIS:PFDoffielddomainandcontroldomainmustbeadded.对于于SIS: 必必须加上磁加上磁场域和控制域的域和控制域的PFD PFDSIS=PFDsen
16、sor+PFDPLC+PFDactuator2004-04-28U.Schuenemann12CommissioningtestofE&ISISCalculation of PFD the problemsPFD的的计算算问题lPFDdataforfieldinstrumentsusuallynotveryreliable(notexperimentallyverifiedforchemicalenvironment).用于用于现场仪表的表的PFD数据通常不是很可靠数据通常不是很可靠(对于化学于化学环境未境未经试验验证).lContributiontoFailureProbability(PF
17、D):对故障概率故障概率的影响因素的影响因素lcalculatedvaluesforPFD:oftennotveryaccurate.lPFD计算算值: 经常不太准常不太准FieldInstruments85%现场仪表LogicSolver(failsafePLC)15%逻辑解答器(故障保护PLC)2004-04-28U.Schuenemann13CommissioningtestofE&ISIS“SIL” requirements for SIS SIS的的“SIL”要求要求SafetyIntegrityLevel(SIL)安全一体化水安全一体化水平平ProbabilityofFailure
18、onDemand(PFD)指令故障概率指令故障概率10.10-0.01operatingandmonitoringfunctions运行和运行和检测功能功能20.01-0.001SIS(“ClassAfunctions”)SIS(“A级功能功能”)30.001-0.000140.0001cannotberealizedbymeansofE&Ifunctionsalone不能不能仅靠靠电仪功功能来能来实现For SIS: international and BASF standards request SIL 2 or SIL 3.对于于SIS: 国国际标准和巴斯夫准和巴斯夫标准要求准要求SIL
19、2 或或 SIL3.2004-04-28U.Schuenemann14CommissioningtestofE&ISISHow to meet “SIL” requirements 如何如何满足足“SIL”要求要求1.Right Instruments: from BASF standard list (field proven) or certified 仪表正确表正确 : 来自巴斯夫来自巴斯夫标准清准清单或核准者或核准者 (SIL 2, TUV certificate,) Devices without systematic design or manufacturing errors w
20、hich can lead to common failure of redundant channels at the same time. 2. Right Design: Redundancy, Diversity. Use design typicals in BASF standard. 设计正确正确: 冗余冗余, 多多样性性. 采用巴斯夫采用巴斯夫标准中的典型准中的典型设计 Redundant (and diverse) channels of sensors and actuators make system tolerant against single passive and
21、 active faults. 3. Testing, Maintenance : perform commissioning test and periodic functional proof tests of SIS. 测试,维护: 进行行SIS调试试验和定期的功能和定期的功能验证试验 In order to discover passive faults of SIS. Test interval depends on design. 2004-04-28U.Schuenemann15CommissioningtestofE&ISISBASF Global Standard Lists
22、 巴斯巴斯夫全球夫全球标准清准清单BASFsStandardDeviceshavepassedextensivelaboratorytestingacc.toIEC770atBASF,Ludwigshafen.arefield-proveninnon-safetyrelatedapplications.haveshownnopassivefaultduringfieldtesting(atleast10devicesmonitoredfor1year).巴斯夫的标准装置已通过广泛的实验室试验,符合路德维希港巴斯夫IEC770标准.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(至少1
23、0台装置被检测了一年).2004-04-28U.Schuenemann16CommissioningtestofE&ISISDesign: Typicals for SIL2 and SIL3 设计: SIL2 和和 SIL3的典型之的典型之处SIL2:lsingle channel design 1oo1can be usedl12 month test intervall可使用可使用单信道信道设计1oo1l12个月的个月的试验间隔隔SIL3:singlechanneldesignnotallowedatleast:2sensors(1oo2)and2actuators.12monthtes
24、tinterval.不允许单信道设计至少2个传感器(1oo2)和2个致动器12个月的试验间隔2004-04-28U.Schuenemann17CommissioningtestofE&ISISPFD of different Architectures 不同不同结构的构的PFDWhatsthebestconfiguration:1oo1,1oo2,2oo2,2oo3,2oo4,?最佳最佳组态是什么是什么?Consider:“failureondemand”-rate (affectsplantsafety) “falsetrip”-rate(affectsplantavailability)须
25、考考虑: “指令故障指令故障”率率 (影响装置安全影响装置安全) “误跳跳闸”率率 (影响装置可用率影响装置可用率)plantsafetyplantsafety 装置安全装置安全装置安全装置安全率率率率plantavailabilityplantavailability 装置可用装置可用装置可用装置可用率率率率HigherHigher高高LowerLower低低2oo22oo2/2oo41oo12oo31oo31oo2/2oo42oo31oo31oo21oo12004-04-28U.Schuenemann18CommissioningtestofE&ISISCommissioning & Pr
26、oof 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lperiodic proof tests periodic proof
27、 tests 周期性的试验周期性的试验lcommissioning 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 Safety 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insta
28、llation 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 te
29、st 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2004-04-28U.Schuenemann19CommissioningtestofE&ISISResponsibilities 职责职责CTA manager CTACTA经理经理P
30、lant Manager装置经装置经理理Project team项目项目组组prepare prepare procedures procedures for for commissioning commissioning testtest准备调试步骤准备调试步骤XXapprove approve procedure for procedure for commissioning commissioning testtest调试的批准手调试的批准手续续XXcarrying out carrying out the the commissioning commissioning testtest
31、调试的实施调试的实施XResponsibilities for Commissioning Test调试试验的责任调试试验的责任2004-04-28U.Schuenemann20CommissioningtestofE&ISISCTA procedure for SIS Commissioning TestSIS调试试验的的CTA程序程序Status:状态状态Draft of CTA procedure completed CTA测试步骤草案测试步骤草案已完成已完成“Commissioning and Periodic Proof Test of E&I SIS”安全仪表系统的调试及周期性试验
32、安全仪表系统的调试及周期性试验lhow to perform commissioning test and periodic proof test 如何进行调试及周期性试验如何进行调试及周期性试验lsample test procedures and check forms 取样测试步骤及检查表格取样测试步骤及检查表格ldefinition of responsibilities between PM, Project team, Operation department 关于装置维护组关于装置维护组，项目组、运行部门的职责的定义项目组、运行部门的职责的定义2004-04-28U.Schuen
33、emann21CommissioningtestofE&ISISLabeling of SIS SIS的的标签SIS and their components (transmitter, power supply, I/O card of a logic solver)shall be clearly markedin the documentation (Z)in the field (Z)SIS及其及其组分分(变送器送器, 电源源,逻辑解答器的解答器的I/O插插件件) 在文件和在文件和现场 (Z) 中均清楚地加以中均清楚地加以标出出.2004-04-28U.Schuenemann22CommissioningtestofE&ISIS Thank you for your attentionDANKE2004-04-28U.Schuenemann23CommissioningtestofE&ISIS
