Implementing Safety Instrumented Burner Management Systems: Challenges and Opportunities

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1 Implementing Safety Instrumented Burner Management Systems: Challenges and Opportunities Mike Scott, PE, CFSE Standards Certification Education & Training Publishing Conferences & Exhibits

2 Presenter Mike Scott, PE, CFSE Executive Vice President Global Process Safety B.S. Mechanical Engineering - University of Maryland Masters of Engineering - University of South Carolina Licensed Professional Engineer - AK, GA, SC, and IL Certified Functional Safety Expert (CFSE) Voting member of ISA S84 committee on Electrical/Electronic/Programmable Electronic Systems (E/E/PES) for Use in Process Safety Applications Chairman of the ISA S84 Working Group on Performance Based Fire & Gas Systems ISA S84 BMS sub-committee member and liaison to the America Boiler Manufacturer s Association (ABMA) and NFPA 86 IEC committee member ISA Safety and Security Division Director - Elect ISA 2015 PCS Symposium Safety Chair ISA Training Course Developer / Instructor ISA Fellow 2

3 SI-BMS Templatization = Significant Cost / Schedule Savings

4 Challenges & Opportunities Applying the safety lifecycle to existing brownfield BMS installations typically results in capital projects to close gaps Possibly new field devices New Safety PLC If BMS upgrades treated as stand alone projects, it will be costly and take many years to remove risk from the business Typically risk analysis will result in missing SIFs, improperly defined SIFs and orders of magnitude differences in SIL targets for like SIFs / unit operations Capital Project Chaos!

5 Safety Lifecycle Tasks Process Hazard Analysis Layer of Protection Analysis Safety Integrity Level (SIL) Selection Safety Requirements Specification SIL Calculations & Verification Functional Test Plans Functional Safety Assessments¹ ¹ Stages 1, 2, & 3 What if I could COPY and PASTE??? 5

6 Instrumentation & Control System Design Tasks Instrument Approved Vendors List in line with SIL Calculation assumptions Instrument Datasheets Instrument Index I/O List Control Panel Design w/ Bill of Materials Control Panel Internal Wiring Field Wiring (Loops / Swing Arms / Schematics) Control System Architecture Diagram Instrumentation and / or Electrical Installation Details Instrument Approved Vendors List in line with SIL Calculation assumptions Instrument Datasheets Instrument Index I/O List Control Panel Design w/ Bill of Materials Control Panel Internal Wiring Field Wiring (Loops / Swing Arms / Schematics) Control System Architecture Diagram Instrumentation and / or Electrical Installation Details What if I could Cable / Conduit Block Diagram Cable Schedule COPY and PASTE??? Software Requirements Specification Logic Solver Configuration Logic Solver Simulation Logic Local Flat Panel Configuration Historian Configuration Remote BPCS HMI Configuration Factory Acceptance Test Procedure / Testing Site Acceptance Test Procedure / Testing Commissioning Test Procedures / Testing 6

7 Operations & Maintenance Tasks Functional Test Plans, Instrument Calibration, Valve Leak Testing loaded and scheduled into the site Computerized Maintenance Management System (CMMS) per Proof Test Coverage assumptions in SIL Calculations What if I could Spare Parts in Stores per Mean Time To Repair assumptions in SIL Calculations COPY and PASTE??? Operations / Maintenance Trained on new SI-BMS Program / personnel in place to track Time in Bypass, Demand Frequency, Cause Frequency, Dangerous Undetected Failures, and Late / Incomplete Testing of SIFs per IEC requirements 7

8 SI-BMS Templatization Methodology Intelligent Engineering Drawings Store Templates Safety Lifecycle Management Toolkit Store Templates Auto MoC Safety / Software Requirements Results Auto Configure Safety PLC Configuration File Auto Test Test Engine 8

9 SI-BMS Templatization Execution Templates Leverage established design standards to ensure high quality, consistent deliverables Testing Develop design methodology that maximizes automated testing for critical information capture Team Dedicated high performing small teams to execute SI-BMS Upgrades 9

10 SI-BMS Templatization Savings Cost Using SI-BMS approach leveraging small, high performing teams to implement standard templates and testing schemes Schedule Operations approval of entire SI-BMS functionality prior to FAT to ensure outage/tar schedule is safely achieved Quality Continuous improvement gains quickly realized by using dedicated teams executing standard designs with automated testing $ Projects moving forward 10

11 COST SAVINGS!!! x 60% Safety Lifecycle I&C System Design O&M Activities Traditional project execution TOTAL What if I could COPY and PASTE??? x 75% x 70% x 35% x 60% 11

12 Questions? Standards Certification Education & Training Publishing Conferences & Exhibits