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SafetySIL Emergency Shutdown Block Valve System

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An Introduction to the SafetySIL Fault-tolerant, On-line Full-stroke Testing, Emergency Shutdown Block Valve System

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SafetySIL Emergency Shutdown Block Valve System

  1. 1. Revolutionizing the way the Process, Production & Pipeline Industries Deal with Safety Critical Systems SafetySafetySILSIL
  2. 2. SafetySafetySILSIL Revolutionizing the way the Oil Field Industries Deal with Safety Critical Systems WELCOME To the World’s First & Only On-Line, Fault-tolerant, Full-Stroke Testing Emergency Shutdown Block Valve System
  3. 3. Revolutionizing the way the Oilfield Industries Deal with Safety Critical Systems SafetySafetySILSIL INTRODUCING: THE SafetySafetySILSIL BLOCK VALVE SYSTEM U. S. Patent No. 6,058,956
  4. 4. Revolutionizing the way the Production Industries Deal with Safety Critical Systems U. S. Patent No. 6,058,956 SafetySafetySILSIL Both Valves Open dP Transmitter at Middle Normal Mode
  5. 5. Revolutionizing the way the Process Industries Deal with Safety Critical Systems U. S. Patent No. 6,058,956 SafetySafetySILSIL “B” Valve Closed dP Transmitter drawn downBernoulli Effect Pulls Down Dead Leg SIL Test – 1st Half Cycle
  6. 6. Revolutionizing the way the Production Industries Deal with Safety Critical Systems U. S. Patent No. 6,058,956 SafetySafetySILSIL Both Valves Open dP Transmitter at Middle Transitioning
  7. 7. Revolutionizing the way the Process Industries Deal with Safety Critical Systems U. S. Patent No. 6,058,956 SafetySafetySILSIL “A” Valve Closed dP Transmitter pulled upBernoulli Effect Pulls Down Dead Leg SIL Test – 2nd Half Cycle
  8. 8. Revolutionizing the way the Process Industries Deal with Safety Critical Systems U. S. Patent No. 6,058,956 SafetySafetySILSIL Both Valves Open dP Transmitter at Middle Return to Normal Mode
  9. 9. SafetySafetySILSIL Revolutionizing the way the Oil Field Industries Deal with Safety Critical Systems Applying the SafetySIL Regulatory Oversight Operator’s Risk Strategy Safety Integrity Level (SIL)
  10. 10. Revolutionizing the way the Process Industries Deal with Safety Critical Systems REQUIRES OPERATORS OF HAZARDOUS PROCESSES TO: • IDENTIFY AND MITIGATE ALL POTENTIALLY DANGEROUS EVENTS • DANGEROUS EVENTS IMPACT SAFETY, HEALTH, AND THE ENVIRONMENT THEY ARE REQUIRED THEN TO EITHER: • REDUCE THE CONSEQUENCES IF THESE EVENTS OCCUR • REDUCE THE PROBABILITY OF THEIR OCCURANCE TO A LEVEL DEEMED “ACCEPTABLE.” SafetySafetySILSIL FEDERAL & STATE REGULATORY OVERSIGHT
  11. 11. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySafetySILSIL OPERATORS RISK STRATEGY PROCESS HAZARD ANALYSIS (PHA) CONSISTS OF: • STUDYING THE PROCESS • REDUCING THE PROBALILITY OF A DANGEROUS EVENT • REDUCING THE RISK TO THE REQUIRED “ACCEPTABLE” LEVEL • SAFETY INSTRUMENTED SYSTEMS (SIS) ARE INSTALLED TO REDUCE RISK • SIS ARE ASSIGNED A SAFETY INTEGRITY LEVEL (SIL)
  12. 12. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySafetySILSIL SAFETY INTEGRITY LEVEL (SIL) BASED ON (3) CHARACTERISTICS OF THE PROCESS AND SIS: 1. SHUTDOWN DEMAND RATE 2. PROBABILITY TO FAIL UPON DEMAND (PFD) 3. TESTING FREQUENCY EACH OF THESE FACTORS CAN BE ADDRESSED TO INCREASE THE SIL OF A SIS
  13. 13. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySafetySILSIL INCREASING SIL ACTIVITIES THAT CAN RESULT IN A HIGHER SIL FOR A SIS: • RE-ENGINEERING PROCESS TO LOWER THE SHUTDOWN DEMAND RATE • INCREASE MEAN TIME BETWEEN FAILURE (MTBF) OF SIS EQUIPMENT • TEST SIS MORE FREQUENTLY
  14. 14. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySafetySILSIL SIL = Testing Frequency (PFD X Demand Rate) SIL RELATIONSHIP DEFINED TESTING FREQUENCY ↑= SIL ↑ PDF ↓ = SIL ↑ DEMAND RATE ↓= SIL ↑
  15. 15. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySafetySILSIL FREQUENCY TESTING EFFECTS SIL IN THE FOLLOWING WAYS: • ANY SYSTEM CAN MEET REQUIRED PFD IF IT IS TESTED FREQUENTLY ENOUGH • FREQUENT FUNCTION TESTING CAUSES PROCESS INTERUPTIONS • PROCESS INTERUPTIONS REDUCE PRODUCTION & REVENUE • PARTIAL STROKE TESTING DECREASES INTERUPTIONS, BUT ALSO DIAGNOSTIC COVERAGE
  16. 16. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySafetySILSIL SIL LEVELS DEFINED RANGES OF (4) LEVELS OF SAFETY INTEGRITY (IEC 61508): •SIL 1 : 0.1 – 0.01 Failures / YR (1% to 10% or RRF 10-100 YRS) •SIL 2 : 0.01 – 0.001 Failures / YR (0.1% to 1% or RRF 100-1,000 YRS) •SIL 3 : 0.001 – 0.0001 Failures / YR (0.01% to 0.1% of RRF 1,000-10,000 YRS) •SIL 4 : 0.0001 – 0.00001 Failures / YR (0.001% to 0.0001% or RRF 10,000-100,000 YRS) (Note: Administrative Procedures/Operator Actions are classed as SIL-1) (Interesting Note: Safety Integrity Level is the same as the number of zeros)
  17. 17. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySafetySILSIL CONTRIBUTIONS TO SIS FAILURES OF THE FINAL CONTROL ELEMENT (BLOCK VALVE): • MAJORITY OF DANGEROUS FAILURES CAUSED BY THE BLOCK VALVE • MAJORITY OF NUISANCE TRIPS CAUSED BY THE BLOCK VALVE • PRIMARY CHALLENGE IS FREQUENCY TESTING THE BLOCK VALVE • ACHIEVING NEAR 100% DIAGNOSTICS WOULD SHUT DOWN THE PROCESS • TESTING SYSTEMS CAN CAUSE COSTLY SPURIOUS/NUISANCE TRIPS Note: Dangerous Failures are classed under “Probability to Fail on Demand” (PDF), Nuisance (spurious) Trips are classed under “Mean Time To Fail Safe” (MTTFS)
  18. 18. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySafetySILSIL
  19. 19. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySafetySILSIL SIS SYSTEM DESIGN WHEN DESIGNING A SIS: • USE EQUIPMENT WITH A LARGE MTBF (DOESN’T FAIL OFTEN) • DESIGN FOR INCREASED TESTING FREQUENCY TO ACHIEVE THE PFD • MOST VULNERABLE PART OF THE SIS IS THE FINAL ELEMENT (THE BLOCK VALVE) LATEST SIS DESIGNS FOR BLOCK VALVES DO NOT SOLVE THE PROBLEM
  20. 20. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySafetySILSIL SIS BLOCK VALVE DESIGN TWO (2) BLOCK VALVES IN SERIES: • INCREASE SAFETY WITHOUT THE NEED TO TEST MORE FREQUENTLY • UNLIKELY THAT BOTH VALVE’S WILL HAVE FAILED AT THE SAME TIME • DOUBLES THE CHANCE FOR A SPURIOUS/NUISANCE TRIP • SIGNIFICANT POTENTIAL FOR LOST REVENUE, (COULD BE MORE COSTLY THAN OTHER ALTERNATIVES)
  21. 21. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySafetySILSIL SIS BLOCK VALVE DESIGN PARALLEL BYPASS AROUND THE BLOCK VALVE: • ALLOWS FOR ON-LINE FULL STROKE TESTING • INCREASES DIAGNOSTIC COVERAGE OF EACH TEST • HUMAN ERROR ON BYPASS CREATES POTENTIAL FOR DANGEROUS FAILURE • LIMITED TO SIL 1 RATING (BECAUSE OF THE HUMAN INTERACTION)
  22. 22. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySafetySILSIL SIS BLOCK VALVE TESTING PARTIAL STROKE TESTING: • BLOCK VALVE IS EXERCISED PARTIALLY CLOSED • TEST PERFORMED WITH MINIMAL PROCESS INTERUPTION • DECREASED DIAGNOSTIC COVERAGE VS. A FULL STROKE TEST • WIDELY ACCEPTED THAT PARTIAL STROKE WILL CATCH 60 – 80% OF FAILURES, BUT WHAT ABOUT THE OTHER 20 – 40%?
  23. 23. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySafetySILSIL SIS BLOCK VALVE TESTING
  24. 24. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySafetySILSIL This screen print from a large, international partial stroke testing manufacturer shows their opinion of Partial Stoke Technology!
  25. 25. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySafetySILSIL SIS BLOCK VALVE TESTING INDUSTRY NEEDS A BLOCK VALVE SYSTEM CAPABLE OF: • ON-LINE TESTING • FULL STROKE TEST • FAULT TOLERANT (NO SPURIOUS/NUISANCE TRIPS, REPAIRABLE ON-LINE) • SIL CAPABLE • NO PROCESS INTERUPTION, REGARDLESS OF THE TESTING FREQUENCY!!!
  26. 26. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySafetySILSIL
  27. 27. Revolutionizing the way the Process Industries Deal with Safety Critical Systems THE SafetySafetySILSIL WHY’S: SafetySafetySILSIL
  28. 28. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySafetySILSIL THE SafetySafetySILSIL WHY’S WHY DOES THE SafetySafetySILSIL INCREASE THE LEVEL OF PROTECTION: • ON-LINE, FULL STROKE TESTING • TESTING AS FREQUENTLY AS REQUIRED TO ACHIEVE ANY SIL, EVEN SIL 4 • NEARLY 100% DIAGNOSTICS, INCLUDING OPERATION OF PLC & I/O MODULES • NO PROCESS INTERUPTION, REGARDLESS OF THE TESTING FREQUENCY!!!
  29. 29. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySafetySILSIL THE SafetySafetySILSIL WHY’S WHY DOES THE SafetySafetySILSIL DECREASE NUISANCE TRIPS: • FAULT TOLERANT TESTING SYSTEM • TESTING WILL DETERMIME IF THERE IS ANY FAILED PART THAT WILL PREVENT EXPECTED OPERATION • FAILED PART CAN BE REPAIRED ON-LINE WITH NO PROCESS INTERUPTION • SPURIOUS/NUISANCE TRIP WILL NOT INTERUP PROCESS
  30. 30. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySafetySILSIL THE SafetySafetySILSIL WHY’S WHY DOES THE SafetySafetySILSIL SAVE YOUR OPERATIONS MONEY: • ELIMINATING SPURIOUS/NUISANCE TRIPS • A TYPICAL SPURIOUS TRIP RATE (STR) CAN BE 3 – 4 PER YEAR • PREVENTION OF JUST (1) SPURIOUS TRIP CAN PAY FOR THE SYSTEM • EACH ADDITIONAL SPURIOUS/NUISANCE TRIP PREVENTED IS PURE PROFIT!
  31. 31. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySafetySILSIL THE SafetySafetySILSIL WHY’S WHY DOES THE SafetySafetySILSIL DECREASE MAINTENANCE COSTS: • BLOCK VALVES CAN BE TESTED WHILE IN OPERATION • NO NEED TO REMOVE A VALVE UNTIL IT FAILS (RUN TO FAIL) • ON-LINE TESTING INSURES THE VALVE’S ARE FUNCTIONING AS EXPECTED • REDUCTION IN MAINTENANCE COSTS ARE PURE PROFIT!
  32. 32. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySafetySILSIL THE SafetySafetySILSIL WHY’S WHY DOES THE SafetySafetySILSIL DECREASE T-I-Cs: • COSTS UPWARDS OF $30K TO $35K TO MOVE ONE SAFETY FUNCTION FROM SIL-1 TO SIL-2, OR FROM SIL-2 TO SIL 3. (MOVING FROM SIL-1 TO SIL 3 CAN COST UP TO $70K. ONE SafetySafetySILSIL FUNCTION CAN PROVIDE SIL-4 • ELIMINATES NEED FOR MULTIPLE SIL-1 LAYERS OF PROTECTION • CAN USE LESS EXPENSIVE VALVES AND OTHER EQUIPMENT (LOWER MTBFS)
  33. 33. Revolutionizing the way the Process Industries Deal with Safety Critical Systems SafetySafetySILSIL THE ONLY: ON-LINE FULL STROKE TESTING FAULT TOLERANT SIL CAPABLE BLOCK VALVE SYSTEM THE REVOLUTION IN FAULT TOLERANT TECHNOLOGY!
  34. 34. Revolutionizing the way the Process, Oilfield & Pipeline Industries Deal with Safety Critical Systems SafetySafetySILSIL SafetySIL, LLC’s PARTNER IN PRODUCTION, FACTORY ACCEPTANCE TESTING AND FIELD SUPPORT FOR • INSTALLATION, • CONFIGURATION • MAINTENANCE • TRAINING

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