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6th Annual Process Solutions User Group Meeting 1

Process SolutionsUser Group Meeting

Trends in Process Safety & Critical ControlPaul Gruhn, PE, CFSEICS Triplex

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Introduction of Speaker

Paul Gruhn, PE CFSE– Safety Systems Specialist for > 18 years– ISA Fellow– Member of ISA SP84 committee– Instructor for ISA’s web, 1, 3 & 5 day courses on

Safety Instrumented Systems– Co-author of ISA book on Safety Instrumented

Systems– Developer of commercial modeling software– Registered Professional Engineer in Texas– Certified Functional Safety Expert

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Question:

• Would you rather learn from the mistakes of others, or make them all yourself?

• How many of you walk your dog without a leash?

Reserved Area for Audience Results To Be Displayed in Barchart Form

~ 1/3 of screen

1. Who me? I don’t even own a dog!2. Always3. Sometimes4. Never

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Question:

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Key “take away”…

“It should not be necessary for each generation to rediscover principles of process safety which the generation before discovered. We must learn from the experience of others rather than learn the hard way. We must pass on to the next generation a record of what we have learned.” Jesse C. Ducommun

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Why Should I Care?

After Three Mile Island, but before Chernobyl, the head of the Soviet Academy of Sciences said,

“Soviet reactors will soon be so safe that they could be installed in Red Square.”

Do you think he’d say that now?

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Why Should I Care?

When the Bhopal plant manager was informed of the accident, he actually said in disbelief,

“The gas leak just can’t be from my plant. The plant is shut down. Our technology just can’t go wrong. We just can’t have leaks.”

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Why Should I Care?

After the Valdez tanker accident, the head of the Alaskan Coast Guard said,

“That’s impossible! We have the perfect navigation system!”

Overconfidence and complacency are dangerous attitudes!

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Accidents & Resulting Regulations

• Flixborough (UK)1974: Safety case requirements in UK

• Bhopal (India)1984: Formation of AIChE CCPS

• Piper Alpha (UK)1988: Safety case requirements offshore

• Pasadena (US)1989: OSHA PSM

• Seveso (Italy)1976: Safety case requirements in Europe

• Texas City (US)1995: Regulations being proposed

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Control System Incidents

• What do you think is the leading factor in the cause of control and safety system accidents?

1. Incorrect / incomplete specs2. Design / implementation errors3. Installation errors4. Changes after commissioning5. Operations / maintenance errors

Reserved Area for Audience Results To Be Displayed in Barchart Form

~ 1/3 of screen

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Control System Incidents

Specification 44%Changes After Commissioning 20%

Design & Implementation 15%

Operations & Maintenance 15%

Installation & Commissioning 6%

From ‘Out Of Control’ A compilation of incidents involving control and safety systems by the UK HSE

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Guidelines, Standards & Regulations

• UK HSE, Programmable Electronic Systems in SafetyRelated Applications, 1987

• AIChE CCPS; Guidelines for Safe Automation of Chemical Processes, 1993

• ANSI/ISA 84; Application of Safety Instrumented Systems for the Process Industries, 1996 & 2004

• IEC 61508 (and 61511); Functional Safety - Safety Related Systems, 1999

• OSHA CFR 1910.119; Process Safety Management of Highly Hazardous Chemicals, 1992

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Safety Instrumented System

A system composed of sensors, logic solvers, and final control elements for the purpose of taking the process to a safe state when pre-determined conditions are violated.

I / PI / P

FTFT

Basic Process Control Basic Process Control System (BPCS) System (BPCS)

InputsInputs OutputsOutputs

ReactorReactor

PTPT1A1A

PTPT1B1B

Safety Instrumented Safety Instrumented System (SIS)System (SIS)

InputsInputs OutputsOutputs

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The “Grandfather Clause”

• What is it?• What does it mean?• How do I interpret it?

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Clause 1.y:

For existing SIS designed and constructed in accordance with codes, standards, or practices prior to the issue of this standard (e.g., ANSI/ISA-84.01-1996), the owner/operator shall determine that the equipment is designed, maintained, inspected, tested, and operating in a safe manner.

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Two Required Steps

• Determine the SIL for each SIF• Determine whether existing SIFs meet

the required SIL• Other issues:

– Have there been prior problems?– Audit your practices– Are the safety systems separate

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General Safety System Trends

• Smaller, distributed systems– Not all systems are 1,000+ I/O!

• Field busses– FF, Profisafe, AS-Interface, HART…

• Integrated control and safety– Total solution from one supplier

• Field device diagnostics– Certified field devices– Partial stroking of valves

• Personnel with certifications– CFSE/CSFP, FSExp, FSEng– ISA developing a program

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Critical Process Control

• Large economic and/or safety concerns– Downtime– Capital– Image / reputation

• Applications:– Nuclear fuel rod control– Nuclear waste disposal– Space launch support facilities control– Turbomachinery (TMC)– Catalytic cracking control

• TMR systems often viewed as the solution– High availability– Fault tolerant

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Training, SIL Determination, SIL Verification & Facilitation

ICS Triplex & Industry Trends

Engineering, Integration & Technical Services

System Assemblyand Staging

System TestProject Engineering

Conceptual Process Review

Perform Hazard

Analysis & Risk Assessment

Apply non-SIS protection layers to

prevent hazard

SISRequired?

Define Target SIL

Develop safety Requirement Specification

SIL Verification

SIS Conceptual Design

According to SRS

SIS Detailed Design

SIS Installation, commissioning & pre-startup accept.Test

Pre-startup safety review

Start-up, operation,

maintenance & periodic testing

SIS Management of

Change

Conceptual Phase Design Phase Operation Phase

Conceptual Process Review

Perform Hazard

Analysis & Risk Assessment

Apply non-SIS protection layers to

prevent hazard

SISRequired?

Define Target SIL

Develop safety Requirement Specification

SIL Verification

SIS Conceptual Design

According to SRS

SIS Detailed Design

SIS Installation, commissioning & pre-startup accept.Test

Pre-startup safety review

Start-up, operation,

maintenance & periodic testing

SIS Management of

Change

Conceptual Phase Design Phase Operation Phase

Single, dual & triplicated systems; small to large

Maintenance Contracts

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Final Thoughts

• Engineering responsibility should not require the stimulation that comes in the wake of catastropheS.C. Florman

• The result of the increased application of hazard analysis has been a 50% reduction in injuries, increased ease of operations, and decreased production stoppagesN. Leveson

• Accidents are not due to lack of knowledge, but failure to use the knowledge we haveT. Kletz

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Final Thoughts

• When a man’s education is finished, he is finishedE.A. Filene

• Those who cannot remember the past, are condemned to repeat itG. Santayana

• Ignoring the problem won’t make it go awayAnonymous

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Safety – The Easy Way!

Do what the French did 200 years ago...They passed a law requiring an explosives manufacturer tolive on the premises... with his family!

Hey, now Hey, now waitwait a minute !a minute !

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Questions?

Paul Gruhn, PE, CFSETraining Managerpaulg@icshou.com