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Partial Stroke Testing A.F.M. Prins Copyright © Yokogawa System Center Europe 2010
Partial Stroke
Testing
A.F.M. Prins
Copyright © Yokogawa System Center Europe
2010
Partial Stroke Testing • PST in a safety related system. As a supplier we have

Partial Stroke Testing

Partial Stroke Testing • PST in a safety related system. As a supplier we have a

• PST in a safety related system.

As a supplier we have a responsibility to our clients.

As a supplier we have a responsibility to our clients. What do they want, and what

What do they want, and what do they really need?

I like to explain the concept based on a simple example:

HIPPS

Copyright © Yokogawa System Center Europe

2010

Copyright © Yokogawa System Center Europe 2010

HIPPS

HIPPS • What is a HIPPS ? HIPPS stands for High Integrity Pressure Protection System A

• What is a HIPPS?

HIPPS stands for High Integrity Pressure Protection System

A HIPPS is a protection device.

Pressure Protection System A HIPPS is a protection device. It acts like a fuse; if the

It acts like a fuse; if the current is too high, the fuse blows.

If the pressure is too high; the valves close.

LO G IC SO LVER M ANIFO LD & TRANSM ITTERS SH UT O FF
LO G IC SO LVER
M ANIFO LD
&
TRANSM ITTERS
SH UT O FF VALVES

The system behind is safe!

Copyright © Yokogawa System Center Europe

2010

Copyright © Yokogawa System Center Europe 2010
A HIPPS is that something NEW? HIPPS are used for more than 30 years. And
A HIPPS is that something NEW?
HIPPS are used for more than 30 years.
And HIPPS are still used, all
around the world.
In all kind of applications.
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2010

Why a HIPPS?

Why a HIPPS?

A HIPPS is, or can be a protection against

Human casualties

Environmental damage

Damage to your Investments

Penalties due to emissions (no flaring policy)

Too high investments.?

Copyright © Yokogawa System Center Europe

Copyright © Yokogawa System Center Europe  
 

2010

When Availability & Integrity Really Count Copyright © Yokogawa System Center Europe 2010
When Availability & Integrity Really Count
Copyright © Yokogawa System Center Europe
2010
SAFETY A.F.M. Prins Copyright © Yokogawa System Center Europe 2010
SAFETY
A.F.M. Prins
Copyright © Yokogawa System Center Europe
2010
process risk Residual Tolerable risk level risk level Risk inherent in process SIS Risk reduction
process risk
Residual
Tolerable
risk level
risk level
Risk inherent
in process
SIS
Risk reduction
Other
External
Process
Risk
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2010

risk graph

risk graph Extent of damage (S) S 1 : Minor injury/damage S 2 : Serious injury,

Extent of damage (S)

S 1 : Minor injury/damage S 2 : Serious injury, death of one person S 3 : Death to several persons S 4 : Catastrophic consequences

Frequency of exposure (A)

A1: Seldom A2: Quite often to permanent

Avoiding of hazard (G)

G1: Possible G2: Almost impossible

Probability of event (W)

W1: High W2: Low W3: Very low

S 1

G 1 A 1 G 2 S 2 G 1 A 2 G 2 A
G
1
A
1
G
2
S
2
G
1
A
2
G
2
A
1
S
3
A
2
S
4

w 1

1

1

2

2

3

3

4

4

w 2

-

1

1

2

2

3

3

4

w 3

-

-

1

1

2

2

3

3

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2010

Copyright © Yokogawa System Center Europe 2010

requirements safety instrumented system

requirements safety instrumented system From the risk graph a Target SIL for the SIS will result

From the risk graph a Target SIL for the SIS will result

The target SIL indicates the maximum average Probability of failure on demand (PFD) the safety system may have

Safety

Integrity

Level

Average Probability of failure on demand

Safety

Availability

Risk Reduction Factor

4

10 -5 to < 10 -4

> 99.99%

> 10 000

3

10 -4 to < 10 -3

99.9 - 99.99%

1 000 - 10 000

2

10 -3 to < 10 -2

99 - 99.9%

100 - 1 000

1

10 -2 to < 10 -1

90 - 99%

10 - 100

0

(Control NA)

Copyright © Yokogawa System Center Europe

2010

Copyright © Yokogawa System Center Europe 2010
Industrial standards for safety IEC 61508 Functional safety of electrical/electronic/programmable electronic

Industrial standards for safety

Industrial standards for safety IEC 61508 Functional safety of electrical/electronic/programmable electronic

IEC 61508

Functional safety of electrical/electronic/programmable electronic safety-related systems (E/E/PE)

Can be applied to all electro-mechanical systems across a wide range of industries.

IEC 61511

Functional safety / Safety Instrumented Systems for the process industry

Targeted at end users implementing SIS for the process industry, it has with more emphases towards PROVEN IN USE

Copyright © Yokogawa System Center Europe

2010

Copyright © Yokogawa System Center Europe 2010
Fault tolerance Copyright © Yokogawa System Center Europe 2010
Fault tolerance
Copyright © Yokogawa System Center Europe
2010
three most significant aspects of IEC 61508 The The Safety Safety Lifecycle Lifecycle The The

three most significant aspects of IEC 61508

three most significant aspects of IEC 61508 The The Safety Safety Lifecycle Lifecycle The The “

TheThe

SafetySafety LifecycleLifecycle

TheThe

PipePipe--toto--PipePipeapproachapproach

TheThe

quantitativequantitative safetysafety assessmentassessment

Copyright © Yokogawa System Center Europe

2010

Copyright © Yokogawa System Center Europe 2010
Periodic proof test interval SIL 10 -5 PFD 10 -4 3 10 -3 2 Required
Periodic proof test interval
SIL
10
-5
PFD
10
-4
3
10
-3
2
Required SIL
10
-2
1
10
-1
T0
T1
T2
T3
T4
Time
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2010

Safety Instrumented System

Safety Instrumented System Pipe to pipe Process pipe Process pipe Logic solver Air Vent. Input Output

Pipe to pipe

Safety Instrumented System Pipe to pipe Process pipe Process pipe Logic solver Air Vent. Input Output
Process pipe Process pipe Logic solver Air Vent. Input Output A A Protection logic O
Process pipe
Process pipe
Logic solver
Air Vent.
Input
Output
A
A
Protection logic
O
D
O
D
Transmitter
Safety
valve
Sensors
Final elements

Copyright © Yokogawa System Center Europe

2010

Copyright © Yokogawa System Center Europe 2010
Quantitative Assessment Total Loop The safety requirements concern (as a minimum) a complete safety loop

Quantitative Assessment

Quantitative Assessment Total Loop The safety requirements concern (as a minimum) a complete safety loop and

Total Loop The safety requirements concern (as a minimum) a complete safety loop and are expressed in Safety Integrity Levels (SIL).

PFD The SIL levels correspond to the average Probability of failure on demand (PFD target) of a complete safety loop.

Quantification Calculations need to be performed to show that a specific safety loop meets its required SIL level.

Copyright © Yokogawa System Center Europe

2010

Copyright © Yokogawa System Center Europe 2010
Probabilities / Safety Integrity Level SIL = Pfd target Pfd loop = Pfd sensors +
Probabilities / Safety Integrity Level
SIL = Pfd target
Pfd loop =
Pfd sensors
+ Pfd logic solver
+ Pfd final elements
Vent
TR
TR
Air
Safety Safety
TR
TR
Interlocks Interlocks
Safety valve
TR
TR
Copyright © Yokogawa System Center Europe
2010
HIPPS Functionality A.F.M. Prins Copyright © Yokogawa System Center Europe 2010
HIPPS Functionality
A.F.M. Prins
Copyright © Yokogawa System Center Europe
2010
Process parameter range Boom? Mechanical safety level Unsafe Condition ESD action Trip level Safety Alarm
Process parameter range
Boom?
Mechanical safety level
Unsafe Condition
ESD action
Trip level
Safety
Alarm Condition
Operator takes action
High alarm level
High level
Control
Normal Condition
Process value
Low level
Time
Copyright © Yokogawa System Center Europe
2010

What is a HIPPS

What is a HIPPS HIPPS, the last line of defense HIPPS ESD PSD DCS ProSafe COM

HIPPS, the last line of defense

HIPPS
HIPPS
ESD PSD DCS
ESD
PSD
DCS
ProSafe COM / Sequent of event / Alarm handling Status information / Analogue values Modbus
ProSafe COM / Sequent of event / Alarm handling
Status information / Analogue values
Modbus RS-232, RS-485
Modbus
Local SOE
MC-562
recorder
AI repeat
4 * 5 W Solenoid driver
4-20 mA
Prog.
Solenoid
Tripamp
Driver
AI-917
2oo3
Output
HIPPS
FO-529
Logic
4-20 mA
Prog.
Tripamp
AI-917
DO-523
Lamp
driver
4-20 mA
Prog.
Prog.
Tripamp
Tripamp
AI-917
AI-917
Alarm
Inputs for:
Logic
Input
Reset, valve test
DI-511
Proximity switches,
8-channel
other
HIPPS
solenoid
local reset
Prog.
P
P
Tripamp
T
T
AI-917
HIPPS
Analog value discrepancy
solenoid
2oo3 manifold
local reset

P

T

T

T
T
T
T
T
T
T
T
T
T
T
T
T

Flow direction

Communication to PLC/DCS/SCADA

HIPPS solenoid local reset HIPPS solenoid local reset
HIPPS
solenoid
local reset
HIPPS
solenoid
local reset
Communication to PLC/DCS/SCADA HIPPS solenoid local reset HIPPS solenoid local reset HIPPS valve HIPPS valve

HIPPS valve

HIPPS valve

Copyright © Yokogawa System Center Europe

2010

Copyright © Yokogawa System Center Europe 2010
Pressure Transmitter A.F.M. Prins Copyright © Yokogawa System Center Europe 2010
Pressure Transmitter
A.F.M. Prins
Copyright © Yokogawa System Center Europe
2010

TÜV SIL 2 Approved

T Ü V SIL 2 Approved
T Ü V SIL 2 Approved Copyright © Yokogawa System Center Europe   2010
T Ü V SIL 2 Approved Copyright © Yokogawa System Center Europe   2010

Copyright © Yokogawa System Center Europe

Copyright © Yokogawa System Center Europe  
 

2010

Measuring Transmitters; certified for use in a SIL 2 loop … 3 transmitters meeting SIL

Measuring

Measuring Transmitters; certified for use in a SIL 2 loop … 3 transmitters meeting SIL 3

Transmitters; certified for use in a SIL 2 loop

3 transmitters meeting SIL 3 SIL 4 voting 2oo3 or 1oo2.

What is the influence of a common fault

Copyright © Yokogawa System Center Europe

2010

Copyright © Yokogawa System Center Europe 2010
MANIFOLD A.F.M. Prins Copyright © Yokogawa System Center Europe 2010
MANIFOLD
A.F.M. Prins
Copyright © Yokogawa System Center Europe
2010
Triple Manifold Copyright © Yokogawa System Center Europe 2010
Triple Manifold
Copyright © Yokogawa System Center Europe
2010
Locking Manifolds Key controlled procedures in single manifolds. Double block and bleed Mechanical interlock
Locking Manifolds
Key controlled procedures in single manifolds.
Double block and bleed
Mechanical interlock
Detection
SIL approval
Copyright © Yokogawa System Center Europe
2010
LOGIC SOLVER A.F.M. Prins Copyright © Yokogawa System Center Europe 2010
LOGIC SOLVER
A.F.M. Prins
Copyright © Yokogawa System Center Europe
2010
Innovation and Continuity 1997 ProSafe-SLS 1990 MagLog 24 1970 MagLog 14 1960 MagLog 3 A
Innovation and Continuity
1997
ProSafe-SLS
1990
MagLog 24
1970
MagLog 14
1960
MagLog 3
A PROVEN CONCEPT
COMFORTABLE IN SAFETY
Copyright © Yokogawa System Center Europe
2010

MagneticMagnetic CoreCore

Magnetic Magnetic Core Core B B H H Rectangular Hysteresis loop F l a t H

B

B

Magnetic Magnetic Core Core B B H H Rectangular Hysteresis loop F l a t H

H

H
H

Rectangular Hysteresis loop

Flat Hysteresis loop

F l a t H y s t e r e s i s l o
F l a t H y s t e r e s i s l o

Anticlockwise magnetisation

y s t e r e s i s l o o p Anticlockwise magnetisation Magnetic

Magnetic particle orientation

y s t e r e s i s l o o p Anticlockwise magnetisation Magnetic

Clockwise magnetisation

Copyright © Yokogawa System Center Europe

2010

Copyright © Yokogawa System Center Europe 2010

ANDANDFunctionFunction

“ “ AND AND ” ” Function Function “Write” “Read” output X & Z Y

“Write”

“Read”

“ “ AND AND ” ” Function Function “Write” “Read” output X & Z Y
“ “ AND AND ” ” Function Function “Write” “Read” output X & Z Y

output

X & Z Y
X
&
Z
Y

Copyright © Yokogawa System Center Europe

2010

Copyright © Yokogawa System Center Europe 2010

ANDAND functionfunction

AND AND function function X Y B-pulse (Clock) A 0 +20V B 0 +20V B A

X

Y

B-pulse

(Clock)

A 0 +20V B 0 +20V B A A
A
0
+20V
B
0
+20V
B
A
A

A-pulse

(Clock)

X Y B-pulse (Clock) A 0 +20V B 0 +20V B A A A-pulse (Clock) 0

0

+20V

A

Z

Logical 0

Logical 1

Logical 0 Logical 1
Logical 0 Logical 1
Logical 0 Logical 1
X & Z Y
X
&
Z
Y

Copyright © Yokogawa System Center Europe

2010

Copyright © Yokogawa System Center Europe 2010
HIPPS Valves A.F.M. Prins Copyright © Yokogawa System Center Europe 2010
HIPPS Valves
A.F.M. Prins
Copyright © Yokogawa System Center Europe
2010
Control of the Valves Solenoids Actuator Valve Copyright © Yokogawa System Center Europe 2010
Control of the Valves
Solenoids
Actuator
Valve
Copyright © Yokogawa System Center Europe
2010
Copyright © Yokogawa System Center Europe 2010
Copyright © Yokogawa System Center Europe
2010
HIPPS Valves Testing of a Valve Partial stroke testing What are we testing? What do

HIPPS Valves

HIPPS Valves Testing of a Valve Partial stroke testing What are we testing? What do we

Testing of a Valve

Partial stroke testing

What are we testing? What do we claim? Is that safe?

Please note that Partial Stroke test can never replace a full stroke test!!!

Partial Stroke test can never replace a full stroke test!!! Full stroke test Copyright © Yokogawa

Full stroke test

Stroke test can never replace a full stroke test!!! Full stroke test Copyright © Yokogawa System

Copyright © Yokogawa System Center Europe

2010

Copyright © Yokogawa System Center Europe 2010
HIPPS Philosophy Isolate the source of the problem rather than releasing to the atmosphere. To
HIPPS Philosophy
Isolate the source of the problem rather than releasing to
the atmosphere.
To do so;
High reliable equipment is required!
A failure in your HIPPS will result in
damage of equipment or endanger the
safety of personnel.
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2010
CERTIFICATION A.F.M. Prins Copyright © Yokogawa System Center Europe 2010
CERTIFICATION
A.F.M. Prins
Copyright © Yokogawa System Center Europe
2010
safety consultancy Wherever Wherever you you need need safety safety expertise, expertise, whether whether in

safety consultancy

safety consultancy Wherever Wherever you you need need safety safety expertise, expertise, whether whether in in

WhereverWherever youyou needneed safetysafety expertise,expertise,

whetherwhether inin bidbid phase,phase,

earlyearly projectproject involvement,involvement,

oror inin projectproject executionexecution

contactcontact aa

SafetySafety AssuranceAssurance && ConsultancyConsultancy

Safety Safety Assurance Assurance & & Consultancy Consultancy Copyright © Yokogawa System Center Europe 2010

Copyright © Yokogawa System Center Europe

2010

Copyright © Yokogawa System Center Europe 2010
Conclusion A.F.M. Prins Copyright © Yokogawa System Center Europe 2010
Conclusion
A.F.M. Prins
Copyright © Yokogawa System Center Europe
2010
Conclusion on PST Copyright © Yokogawa System Center Europe 2010
Conclusion on PST
Copyright © Yokogawa System Center Europe
2010
Conclusion In general you can say: A well designed HIPPS, not only saves money but

Conclusion

Conclusion In general you can say: A well designed HIPPS, not only saves money but “makes

In general you can say:

A well designed HIPPS,

Conclusion In general you can say: A well designed HIPPS, not only saves money but “makes

not only saves money but

“makes the world a little safer after all”.

Copyright © Yokogawa System Center Europe

2010

Copyright © Yokogawa System Center Europe 2010
Thank you for your attention. Commitment means building the future to last. Copyright © Yokogawa
Thank you for your attention. Commitment means building the future to last. Copyright © Yokogawa

Thank you for your attention.

Thank you for your attention. Commitment means building the future to last. Copyright © Yokogawa System

Commitment means building the future to last.

Copyright © Yokogawa System Center Europe

2010

Copyright © Yokogawa System Center Europe 2010