安全儀表系統(tǒng)簡介.ppt

2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,1,Introduction to E&I Safety Instrumented Systems (SIS) 電儀安全儀表系統(tǒng)(SIS) 介紹,2004-04-28 Ulrich Schuenemann BYC Nanjing BYC 南京 尤瑞奇 舒曼 CTA Department E&I maintenance EOEG 電儀維修EOEG CTA部,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,2,Control loops 控制回路 DCS Monitoring functions 檢測功能 DCS Interlocks needed for smooth operation DCS, (ESD) 順利運(yùn)行所需的連鎖 Interlocks related to plant Safety ESD 與裝置安全有關(guān)的連鎖,There are different E&I functions 電儀功能各不相同,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,3,What are E&I S.I.S. 什么是電儀S.I.S?,E&I Safety Instrumented Systems (S.I.S.): 電儀安全儀表系統(tǒng) S.I.S. prevent 安全儀表系統(tǒng)用于防止： personnel injury 人身傷害或 environmental damage 環(huán)境破壞 caused by a not tolerable fault state of the plant 由裝置的不可接受的故障所造成 S.I.S. are defined in the Safety Review Step 2. 安全儀表系統(tǒng)是在安全風(fēng)險評估的第二步中定義的,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,4,Classification of E&I functions 電儀功能的分類,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,5,Definition of SIS: Safety Review step 2 SIS的定義: 安全審查步驟2,SEVERITY 嚴(yán)重性 S1 Potential for one or more fatalities S2 Potential for one or more serious injuries (irreversible) S3 Potential for one or more lost time injuries S4 Potential for minor injuries, or irritation E&I SIS can be used for “risk class B and C”. 電儀SIS可用于 “B級和C級風(fēng)險”,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,6,Example: E&I Safety Review 2 Checklist 實(shí)例: 電儀安全審查2檢查清單,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,7,Failures of a S.I.S. S.I.S的故障,Active error triggers off the safety function for no reason plant is switched back to safe operation reduction of production availability 有源故障 -無緣無故觸發(fā)安全功能 -裝置切回到安全運(yùn)行 -生產(chǎn)運(yùn)行可用率降低,Passive error 無源故障 inhibits the required safety function plant continues operation although it should be switched off impacting the process safety,adversely affecting the safety function 對安全功能產(chǎn)生不利影響,no adverse effect on the safety function 對安全功能無不利影響,Failure 故障,Time-averaged probability for a passive fault : PFD “Probability of Failure on Demand” 無源故障的時間平均可能性: PFD”指令故障的可能性“,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,8,Components of a SIS SIS的組分,Shut-Down System 停車系統(tǒng) Logic in Failsafe PLC or Hardwired system 在故障安全型可編程控制器或硬接線系統(tǒng)中的邏輯,Redundant sensors 冗余的傳感器,Valve 閥門,Solenoid valve 電磁閥,Instrument air supply 儀表氣源,Rack Room 機(jī)柜間,Field 現(xiàn)場,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,9,Passive Faults of sensors and actuators 傳感器和致動器的無源故障,mass flow meter after pressure pulse 壓力脈沖下游的 質(zhì)量流量計,lost control valve plug,control valve plug, damaged by cavitation,restriction orifice, deformed by flow,限流孔板,限流孔,限流孔板, 流量造成的變形,調(diào)節(jié)閥閥塞,空穴造成的損壞,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,10,Some mathematics 一些算法,TI Test Interval between functional tests of SIS, time needed to discover dangerous faults SIS功能測試之間的時間間隔, 發(fā)現(xiàn)危險故障需要的時間 MTBF Mean Time Between Failure of an equipment 設(shè)備故障之間的平均時間 l = 1/ MTBF failure rate 故障率 Pf (t) Probability of failure (to function). For constant failure rates l : Pf (t) = (1 e-l t ) 故障概率(對功能而言).恒定故障率 l : Pf (t) = (1 e-l t ) PFD Probability of Failure on Demand = Pf (t) , time averaged over test interval TI 指令故障概率= Pf (t) , 時間間隔TI的平均時間 PFD = 1/TI 0TI Pf (t) dt,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,11,PFD Probability of Failure on Demand PFD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 自上次功能試驗(yàn)以來經(jīng)過時間 t 后 ,發(fā)現(xiàn)設(shè)備處在危險故障狀態(tài)的概率.,Pf (t) = (1 e-l t ),time average 時間平均值,PFD Probability of Failure on demand PFD指令故障概率,PFD depends on failure rate of equipment AND test interval. PFD取決于設(shè)備AND試驗(yàn)間隔的故障率,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,12,Calculation of PFD PFD的計算,PFD calculation of an individual equipment easy, if you have test interval failure rate (given by supplier) 如有試驗(yàn)間隔和故障率(供貨方提供), 則某個設(shè)備的PFD計算就不難 PFD-calculation for more complex configurations (2oo3 etc. ) can be done using simple statistical models: Good for comparing different configurations. 用簡單的統(tǒng)計模型可進(jìn)行較復(fù)雜的配置(2003等)的PFD計算 For SIS: PFD of field domain and control domain must be added. 對于SIS: 必須加上磁場域和控制域的PFD PFDSIS = PFDsensor + PFDPLC + PFDactuator,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,13,Calculation of PFD the problems PFD的計算問題,PFD data for field instruments usually not very reliable (not experimentally verified for chemical environment). 用于現(xiàn)場儀表的PFD數(shù)據(jù)通常不是很可靠(對于化學(xué)環(huán)境未經(jīng)試驗(yàn)驗(yàn)證). Contribution to Failure Probability (PFD):對故障概率的影響因素 calculated values for PFD: often not very accurate. PFD計算值: 經(jīng)常不太準(zhǔn),Field Instruments 85 % 現(xiàn)場儀表,Logic Solver (failsafe PLC) 15 % 邏輯解答器 (故障保護(hù)PLC),2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,14,“SIL” requirements for SIS SIS的“SIL”要求,For SIS: international and BASF standards request SIL 2 or SIL 3. 對于SIS: 國際標(biāo)準(zhǔn)和巴斯夫標(biāo)準(zhǔn)要求SIL2 或 SIL3.,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,15,How to meet “SIL” requirements 如何滿足“SIL”要求,Right Instruments: from BASF standard list (field proven) or certified 儀表正確 : 來自巴斯夫標(biāo)準(zhǔn)清單或核準(zhǔn)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: Redundancy, Diversity. Use design typicals in BASF standard. 設(shè)計正確: 冗余, 多樣性. 采用巴斯夫標(biāo)準(zhǔn)中的典型設(shè)計 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. 測試,維護(hù): 進(jìn)行SIS調(diào)試試驗(yàn)和定期的功能驗(yàn)證試驗(yàn) In order to discover passive faults of SIS. Test interval depends on design.,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,16,BASF Global Standard Lists 巴斯夫全球標(biāo)準(zhǔn)清單,BASFs Standard Devices have passed extensive laboratory testing acc. to IEC770 at BASF, Ludwigshafen. are field-proven in non-safety related applications. have shown no passive fault during field testing (at least 10 devices monitored for 1 year). 巴斯夫的標(biāo)準(zhǔn)裝置 已通過廣泛的實(shí)驗(yàn)室試驗(yàn),符合路德維希港巴斯夫IEC770標(biāo)準(zhǔn). 在相關(guān)危險應(yīng)用中經(jīng)過現(xiàn)場驗(yàn)證. 在現(xiàn)場測試中未出現(xiàn)無源故障 (至少10臺裝置被檢測了一年).,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,17,Design: Typicals for SIL2 and SIL3 設(shè)計: SIL2 和 SIL3的典型之處,SIL2: single channel design 1oo1 can be used 12 month test interval 可使用單信道設(shè)計1oo1 12個月的試驗(yàn)間隔,SIL3: single channel design not allowed at least: 2 sensors (1oo2) and 2 actuators. 12 month test interval. 不允許單信道設(shè)計 至少2個傳感器(1oo2)和2個致動器 12個月的試驗(yàn)間隔,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,18,PFD of different Architectures 不同結(jié)構(gòu)的PFD,Whats the best configuration: 1oo1, 1oo2, 2oo2, 2oo3, 2oo4, ? 最佳組態(tài)是什么? Consider: “failure on demand”-rate (affects plant safety) “false trip”-rate (affects plant availability) 須考慮: “指令故障”率 (影響裝置安全) “誤跳閘”率 (影響裝置可用率),plant safety 裝置安全率,plant availability 裝置可用率,Higher高,Lower低,2oo2,2oo2 / 2oo4,1oo1,2oo3,1oo3,1oo2 / 2oo4,2oo3,1oo3,1oo2,1oo1,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,19,Commissioning & Proof Testing of E&I S.I.S. 安全儀表系統(tǒng)的調(diào)試及試驗(yàn),All International and BASF standards for SIS require a documented tests 所有有關(guān)的國際標(biāo)準(zhǔn)或BASF標(biāo)準(zhǔn)均要求對安全儀表系統(tǒng)進(jìn)行有文檔記錄的測試 periodic proof tests 周期性的試驗(yàn) commissioning test before startup 開車前的調(diào)試,Objective for Commissioning Test: 調(diào)試的目的是為了檢查： design according to Safety Review 2 設(shè)計遵照安全風(fēng)險評估第二步所要求 installation ok 安裝正確 parameter settings ok 參數(shù)設(shè)置無誤 function of instruments (sensors and actuators) ok 儀表功能（傳感器,執(zhí)行器）均正確無誤 logic action correct 邏輯動作正確,Commissioning test of S.I.S. will be main task for CTA PM during commissioning of plants. 在裝置調(diào)試期間，安全儀表系統(tǒng)的調(diào)試是電儀經(jīng)理的主要任務(wù),2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,20,Responsibilities for Commissioning Test