安全仪表系统简介.ppt

2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,1,Introduction to E&I Safety Instrumented Systems(SIS)电仪安全仪表系统(SIS)介绍,2004-04-28Ulrich Schuenemann BYC NanjingBYC 南京尤瑞奇 舒曼CTA DepartmentE&I maintenance EOEG电仪维修EOEG CTA部,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,2,Control loops 控制回路 DCS Monitoring functions 检测功能DCSInterlocks needed for smooth operation DCS,(ESD)顺利运行所需的连锁Interlocks 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,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,3,What are E&I S.I.S.什么是电仪S.I.S?,E&I Safety Instrumented Systems(S.I.S.):电仪安全仪表系统S.I.S.prevent 安全仪表系统用于防止：personnel injury 人身伤害或 environmental damage 环境破坏caused by a not tolerable fault state of the plant 由装置的不可接受的故障所造成 S.I.S.are defined in the Safety Review Step 2.安全仪表系统是在安全风险评估的第二步中定义的,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,4,Classification of E&I functions 电仪功能的分类,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,5,Definition of SIS:Safety Review step 2SIS的定义: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(irreversible)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”,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,6,Example:E&I Safety Review 2 Checklist实例:电仪安全审查2检查清单,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,7,Failures of a S.I.S.的故障,Active errortriggers off the safety function for no reasonplant is switched back to safe operationreduction of production availability有源故障-无缘无故触发安全功能-装置切回到安全运行-生产运行可用率降低,Passive error 无源故障inhibits the required safety function plant continues operation although it should be switched offimpacting the process safety,adversely affecting the safety function 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,Failure 故障,Time-averaged probability for a passive fault:PFD“Probability of Failure on Demand”无源故障的时间平均可能性: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的组分,Shut-Down System 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 机柜间,Field 现场,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,9,Passive Faults of sensors and actuators传感器和致动器的无源故障,mass flow meter after pressure pulse压力脉冲下游的质量流量计,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,流量造成的变形,调节阀阀塞,空穴造成的损坏,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,10,Some mathematics 一些算法,TITest Interval between functional tests of 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)PFDProbability 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)dt,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,11,PFD Probability of Failure on DemandPFD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,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,12,Calculation of PFD PFD的计算,PFD calculation of an individual equipment easy,if you havetest interval failure rate(given by supplier)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PFD-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(2003等)的PFD计算For SIS:PFD of field domain and control domain must be added.对于SIS:必须加上磁场域和控制域的PFD PFDSIS=PFDsensor+PFDPLC+PFDactuator,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,13,Calculation of PFD the problemsPFD的计算问题,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(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 Instruments85%现场仪表,Logic Solver(failsafe PLC)15%逻辑解答器(故障保护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.对于SIS:国际标准和巴斯夫标准要求SIL2 或 SIL3.,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,15,How to meet“SIL”requirements 如何满足“SIL”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:Redundancy,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.,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,16,BASF Global Standard Lists 巴斯夫全球标准清单,BASFs Standard Deviceshave 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10台装置被检测了一年).,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,17,Design:Typicals for SIL2 and SIL3 设计:SIL2 和 SIL3的典型之处,SIL2:single channel design 1oo1can be used12 month test interval可使用单信道设计1oo112个月的试验间隔,SIL3:single channel design not allowed at least:2 sensors(1oo2)and 2 actuators.12 month test interval.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,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,18,PFD of different Architectures 不同结构的PFD,Whats 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(影响装置可用率),plant safety 装置安全率,plant availability 装置可用率,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.安全仪表系统的调试及试验,All International and BASF standards for SIS require a documented tests所有有关的国际标准或BASF标准均要求对安全仪表系统进行有文档记录的测试periodic proof tests 周期性的试验commissioning test before startup 开车前的调试,Objective for Commissioning Test:调试的目的是为了检查：design according to Safety Review 2 设计遵照安全风险评估第二步所要求installation ok 安装正确parameter settings ok 参数设置无误function of instruments(sensors and actuators)ok 仪表功能（传感器,执行器）均正确无误logic action correct 逻辑动作正确,Commissioning test of S.I.S.will be main task for CTA PM during commissioning 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,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,20,Responsibilities for Commissioning Test调试试验的责任,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,21,CTA procedure for SIS Commissioning TestSIS调试试验的CTA程序,Status:状态Draft of CTA procedure completed CTA测试步骤草案已完成“Commissioning and Periodic Proof Test of E&I SIS”安全仪表系统的调试及周期性试验how to perform commissioning test and periodic proof test 如何进行调试及周期性试验sample test procedures and check forms 取样测试步骤及检查表格definition of responsibilities between PM,Project team,Operation department 关于装置维护组，项目组、运行部门的职责的定义,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,22,Labeling of SIS SIS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及其组分(变送器,电源,逻辑解答器的I/O插件)在文件和现场(Z)中均清楚地加以标出.,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,23,Thank you for your attention,DANKE,