This document discusses methods for selecting the appropriate safety integrity level (SIL) for burner management systems. It presents a 7-step quantitative method to estimate consequences and likelihood of failures in order to determine the required SIL. The method involves calculating potential effect zones from vapor cloud explosions or pool fires, estimating personnel density within effect zones, performing layer of protection analyses to determine failure frequencies, and using these factors to calculate the probability of failure on demand and corresponding risk reduction factor to select the SIL. The document provides an example calculation for a natural gas-fired boiler to demonstrate how easily the 7-step method can be applied in practice.
Maximizing the return on your control investment meet the experts sessions part2Emerson Exchange
The design and commissioning of the controls associated with a continuous or batch process directly impact plant operating efficiency and production quality and throughput. In this session we review techniques that may be used to identify control opportunities to reduce production costs, minimize variations in product quality and to maximize production within the limits set by market demand. Several common application examples from the process industry will be used to illustrate how plant production rate and product quality are directly influenced by process control variation and constraints in plant operation. Starting with an assessment of control loop utilization and automatic control performance, a step by step process is outlined that may be used to identifying and addressing areas where it is possible to justified the time and material costs required to improve control performance. In particular, information will be provided on how to quickly tune single loop control of self-regulating or integrating process and to recognize when variations in control loop performance are not associated with loop tuning. An overview will be provided of tools and techniques that may be used to achieve best control performance over a wide variety of operating conditions. Also, guidance will be provided on when it is possible to justify the cost associated with the installation and commissioning of multi-loop techniques such as feedforward control, ratio and override control. The steps required to commission multi-loop control strategies will be address along with common mistakes to avoid. Also, input will be provided on how to recognize when advanced control techniques such as Fuzzy logic or MPC are needed to achieve the desired control performance. At the end of this session a drawing will be held to give away 10 copies of “Control Loop Foundation – Batch and Continuous Processes”. Many of the ideas discussed in this session are addressed in this book.
Advanced control foundation tools and techniquesEmerson Exchange
A new book on advanced control fundamental will be published by ISA in September, 2012. This book addresses all the advanced control products that are included in the DeltaV control system or are planned for a future DeltaV release. In this session two of the authors present and discuss key areas addressed in the book and demonstrate web site that accompanies the book.
Commissioning highly interactive process an approach for tuning control loopsEmerson Exchange
The size of the process equipment used in a pilot plant dictates a little buffering and interaction between process units. We examine a skid mounted high temperature CO2 recovery process with a high degree of process interaction. An effective tuning approach provided high performance control. A dynamic process simulation optimized performance by exploring various control strategies.
This presentation gives the information about introduction to control systems
Subject: Control Engineering as per VTU Syllabus of Aeronautical Engineering.
Notes Compiled By: Hareesha N Gowda, Assistant Professor, DSCE, Bengaluru-78.
Disclaimer:
The contents used in this presentation are taken from the text books mentioned in the references. I do not hold any copyrights for the contents. It has been prepared to use in the class lectures, not for commercial purpose.
Introduction, Feature of Control System, Requirement of Good Control System, Types of Control System, Open-loop control system, Closed-loop control system, Comparison of Closed-Loop and Open-Loop Control System, Signal flow graph, Conversion of Block Diagrams into Signal Flow Graphs, and Questions.
Practical Advanced Process Control for Engineers and TechniciansLiving Online
In today's environment, the processing, refining and petrochemical business is becoming more and more competitive and every plant manager is looking for the best quality products at minimum operating and investment costs. The traditional PID loop is used frequently for much of the process control requirements of a typical plant. However there are many drawbacks in using these, including excessive dead time which can make the PID loop very difficult (or indeed impossible) to apply.
Advanced Process Control (APC) is thus essential today in the modern plant. Small differences in process parameters can have large effects on profitability; get it right and profits continue to grow; get it wrong and there are major losses. Many applications of APC have pay back times well below one year. APC does require a detailed knowledge of the plant to design a working system and continual follow up along the life of the plant to ensure it is working optimally. Considerable attention also needs to be given to the interface to the operators to ensure that they can apply these new technologies effectively as well.
WHO SHOULD ATTEND?
Automation engineers
Chemical engineers
Chemical plant technologists
Electrical engineers
Instrumentation and control engineers
Process control engineers
Process engineers
Senior technicians
System integrators
MORE INFORMATION: http://www.idc-online.com/content/practical-advanced-process-control-engineers-and-technicians-26
Recovery from a process saturation condition benefits of using delta v pid_plusEmerson Exchange
The PIDPlus option of the PID function block in the DeltaV v11.3 allows improved recovery from a process saturation condition. In this workshop the technical basis for the change in the PID are presented. The impact this has on the time required to get to setpoint is examined and the improvement in response for the surge control will be demonstration using a synamic compressor simulation.
Maximizing the return on your control investment meet the experts sessions pa...Emerson Exchange
The design and commissioning of the controls associated with a continuous or batch process directly impact plant operating efficiency and production quality and throughput. In this session we review techniques that may be used to identify control opportunities to reduce production costs, minimize variations in product quality and to maximize production within the limits set by market demand. Several common application examples from the process industry will be used to illustrate how plant production rate and product quality are directly influenced by process control variation and constraints in plant operation. Starting with an assessment of control loop utilization and automatic control performance, a step by step process is outlined that may be used to identifying and addressing areas where it is possible to justified the time and material costs required to improve control performance. In particular, information will be provided on how to quickly tune single loop control of self-regulating or integrating process and to recognize when variations in control loop performance are not associated with loop tuning. An overview will be provided of tools and techniques that may be used to achieve best control performance over a wide variety of operating conditions. Also, guidance will be provided on when it is possible to justify the cost associated with the installation and commissioning of multi-loop techniques such as feedforward control, ratio and override control. The steps required to commission multi-loop control strategies will be address along with common mistakes to avoid. Also, input will be provided on how to recognize when advanced control techniques such as Fuzzy logic or MPC are needed to achieve the desired control performance. At the end of this session a drawing will be held to give away 10 copies of “Control Loop Foundation – Batch and Continuous Processes”. Many of the ideas discussed in this session are addressed in this book.
Utilizing DeltaV Advanced Control Innovations to Improve Control PerformanceEmerson Exchange
Many functions of the DeltaV system are unique in the process industry. In this presentation we explore and discuss innovative features of the DeltaV PID and embedded Advanced Control products that can be applied to improve control performance. In particular, PID options are addressed that enhance cascade and override applications and allow effective single loop control using a sampled or wireless measurement. Application examples are used to illustrate how MPC can be easily added and commissioned online with no changes in the existing control strategy. Also, continuous data analytics is used an example that illustrates how future tools will enable improvements to be made in plant operations.
JEPL, an engineering arm of Jasubhai Group, today, has pioneered the fields of instrumentation, equipment and engineering for process industries. Driven with an utmost desire to 'make a difference' in customers' lives with the best possible solutions, the company steadily developed its operations and established different divisions, including Combustion Engineering, Contract Manufacturing, Material Handling, Process Equipment, Process Automation, Oil & Gas Service and Water Technology.
Focused on providing Combustion Technology and Turnkey Solutions to OEMs and end users, Jasubhai Engineering specialise in:
Handling all types of fuels - such as Light Fuel Oils, Heavy Fuel Oils, Gases - LPG, Refinery Gas, Bio-gas, Lean Waste - Gases, etc.
Multi-fuel fired burners for flexibility and operational economy.
Robust and high efficiency burners operating at low excess air and optimise fuel consumption.
Supplies to major OEMs of Boilers & Process heating systems to all Industry Segments like Power, Paper, Sugar, Minerals, Cement, Refinery, Chemicals, Petrochemicals and Metals to name a few.
Backward and forward integration to suit existing systems.
Feel free to contact me (benjaminkyalo@dewarlos.co.ke / +254735211022) we discuss more on your application.
Maximizing the return on your control investment meet the experts sessions part2Emerson Exchange
The design and commissioning of the controls associated with a continuous or batch process directly impact plant operating efficiency and production quality and throughput. In this session we review techniques that may be used to identify control opportunities to reduce production costs, minimize variations in product quality and to maximize production within the limits set by market demand. Several common application examples from the process industry will be used to illustrate how plant production rate and product quality are directly influenced by process control variation and constraints in plant operation. Starting with an assessment of control loop utilization and automatic control performance, a step by step process is outlined that may be used to identifying and addressing areas where it is possible to justified the time and material costs required to improve control performance. In particular, information will be provided on how to quickly tune single loop control of self-regulating or integrating process and to recognize when variations in control loop performance are not associated with loop tuning. An overview will be provided of tools and techniques that may be used to achieve best control performance over a wide variety of operating conditions. Also, guidance will be provided on when it is possible to justify the cost associated with the installation and commissioning of multi-loop techniques such as feedforward control, ratio and override control. The steps required to commission multi-loop control strategies will be address along with common mistakes to avoid. Also, input will be provided on how to recognize when advanced control techniques such as Fuzzy logic or MPC are needed to achieve the desired control performance. At the end of this session a drawing will be held to give away 10 copies of “Control Loop Foundation – Batch and Continuous Processes”. Many of the ideas discussed in this session are addressed in this book.
Advanced control foundation tools and techniquesEmerson Exchange
A new book on advanced control fundamental will be published by ISA in September, 2012. This book addresses all the advanced control products that are included in the DeltaV control system or are planned for a future DeltaV release. In this session two of the authors present and discuss key areas addressed in the book and demonstrate web site that accompanies the book.
Commissioning highly interactive process an approach for tuning control loopsEmerson Exchange
The size of the process equipment used in a pilot plant dictates a little buffering and interaction between process units. We examine a skid mounted high temperature CO2 recovery process with a high degree of process interaction. An effective tuning approach provided high performance control. A dynamic process simulation optimized performance by exploring various control strategies.
This presentation gives the information about introduction to control systems
Subject: Control Engineering as per VTU Syllabus of Aeronautical Engineering.
Notes Compiled By: Hareesha N Gowda, Assistant Professor, DSCE, Bengaluru-78.
Disclaimer:
The contents used in this presentation are taken from the text books mentioned in the references. I do not hold any copyrights for the contents. It has been prepared to use in the class lectures, not for commercial purpose.
Introduction, Feature of Control System, Requirement of Good Control System, Types of Control System, Open-loop control system, Closed-loop control system, Comparison of Closed-Loop and Open-Loop Control System, Signal flow graph, Conversion of Block Diagrams into Signal Flow Graphs, and Questions.
Practical Advanced Process Control for Engineers and TechniciansLiving Online
In today's environment, the processing, refining and petrochemical business is becoming more and more competitive and every plant manager is looking for the best quality products at minimum operating and investment costs. The traditional PID loop is used frequently for much of the process control requirements of a typical plant. However there are many drawbacks in using these, including excessive dead time which can make the PID loop very difficult (or indeed impossible) to apply.
Advanced Process Control (APC) is thus essential today in the modern plant. Small differences in process parameters can have large effects on profitability; get it right and profits continue to grow; get it wrong and there are major losses. Many applications of APC have pay back times well below one year. APC does require a detailed knowledge of the plant to design a working system and continual follow up along the life of the plant to ensure it is working optimally. Considerable attention also needs to be given to the interface to the operators to ensure that they can apply these new technologies effectively as well.
WHO SHOULD ATTEND?
Automation engineers
Chemical engineers
Chemical plant technologists
Electrical engineers
Instrumentation and control engineers
Process control engineers
Process engineers
Senior technicians
System integrators
MORE INFORMATION: http://www.idc-online.com/content/practical-advanced-process-control-engineers-and-technicians-26
Recovery from a process saturation condition benefits of using delta v pid_plusEmerson Exchange
The PIDPlus option of the PID function block in the DeltaV v11.3 allows improved recovery from a process saturation condition. In this workshop the technical basis for the change in the PID are presented. The impact this has on the time required to get to setpoint is examined and the improvement in response for the surge control will be demonstration using a synamic compressor simulation.
Maximizing the return on your control investment meet the experts sessions pa...Emerson Exchange
The design and commissioning of the controls associated with a continuous or batch process directly impact plant operating efficiency and production quality and throughput. In this session we review techniques that may be used to identify control opportunities to reduce production costs, minimize variations in product quality and to maximize production within the limits set by market demand. Several common application examples from the process industry will be used to illustrate how plant production rate and product quality are directly influenced by process control variation and constraints in plant operation. Starting with an assessment of control loop utilization and automatic control performance, a step by step process is outlined that may be used to identifying and addressing areas where it is possible to justified the time and material costs required to improve control performance. In particular, information will be provided on how to quickly tune single loop control of self-regulating or integrating process and to recognize when variations in control loop performance are not associated with loop tuning. An overview will be provided of tools and techniques that may be used to achieve best control performance over a wide variety of operating conditions. Also, guidance will be provided on when it is possible to justify the cost associated with the installation and commissioning of multi-loop techniques such as feedforward control, ratio and override control. The steps required to commission multi-loop control strategies will be address along with common mistakes to avoid. Also, input will be provided on how to recognize when advanced control techniques such as Fuzzy logic or MPC are needed to achieve the desired control performance. At the end of this session a drawing will be held to give away 10 copies of “Control Loop Foundation – Batch and Continuous Processes”. Many of the ideas discussed in this session are addressed in this book.
Utilizing DeltaV Advanced Control Innovations to Improve Control PerformanceEmerson Exchange
Many functions of the DeltaV system are unique in the process industry. In this presentation we explore and discuss innovative features of the DeltaV PID and embedded Advanced Control products that can be applied to improve control performance. In particular, PID options are addressed that enhance cascade and override applications and allow effective single loop control using a sampled or wireless measurement. Application examples are used to illustrate how MPC can be easily added and commissioned online with no changes in the existing control strategy. Also, continuous data analytics is used an example that illustrates how future tools will enable improvements to be made in plant operations.
JEPL, an engineering arm of Jasubhai Group, today, has pioneered the fields of instrumentation, equipment and engineering for process industries. Driven with an utmost desire to 'make a difference' in customers' lives with the best possible solutions, the company steadily developed its operations and established different divisions, including Combustion Engineering, Contract Manufacturing, Material Handling, Process Equipment, Process Automation, Oil & Gas Service and Water Technology.
Focused on providing Combustion Technology and Turnkey Solutions to OEMs and end users, Jasubhai Engineering specialise in:
Handling all types of fuels - such as Light Fuel Oils, Heavy Fuel Oils, Gases - LPG, Refinery Gas, Bio-gas, Lean Waste - Gases, etc.
Multi-fuel fired burners for flexibility and operational economy.
Robust and high efficiency burners operating at low excess air and optimise fuel consumption.
Supplies to major OEMs of Boilers & Process heating systems to all Industry Segments like Power, Paper, Sugar, Minerals, Cement, Refinery, Chemicals, Petrochemicals and Metals to name a few.
Backward and forward integration to suit existing systems.
Feel free to contact me (benjaminkyalo@dewarlos.co.ke / +254735211022) we discuss more on your application.
Smarter, self-diagnostic digital safety switches for temperature, pressure, flow, and level eliminate some of the risks associated with mechanical or pneumatic actuated devices.
Orion Instruments Jupiter Magnetostrictive Level TransmitterMiller Energy, Inc.
The Jupiter JM4 Magnetostrictive level transmitter from Orion Instruments is the newest and most advanced level instrument to date. The JM4 is available as a direct insertion option, as well as an external mount on any Orion magnetic level indicator (MLI) or modular instrumentation bridle. With an improved design, unparalleled performance, and a collection of new and innovative features, the JM4 provides safer, simpler, and smarter measurement in total and interface level applications.
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Beyond the trend of using IP as the “up to date technology” for SCADA (IEC 60870-5-104) and protections scheme integrated to a centralized management of the load (Sinchrophasors PMU), there is the need to approach the automatic switching and intrinsic autonomy of routing algorithms to provide smart capability to the communications network [1]. For long time IP equipment manufacturers have been trying to penetrate the electrical utilities with partial success, they were able to support only added value services as IP Video, VoIP and corporate IP traffic which is are not “critical” or essential to the electrical power system operation.
On this paper is presented a theoretical-practical evaluation of the MPLS-TP protocol which offers an IP platform according to the complimentary services requirements (high bandwidth) as well for reliable channels features through the emulation of TDM systems with delay, symmetry and self-healing switching in order to warrant the correct operation of critical services as Teleprotection, Differential Relays and Sinchrophasors.
Key time measurements will be presented which certifies the theoretical reliability of MPLS-TP as main IP communication platform in electrical transmission systems.
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1. 1
Burner Management System Safety Integrity Level Selection
Michael D. Scott, P.E.
Principal Safety System Specialist
AE Solutions
P.O. Box 26566
Greenville, SC 29616
KEYWORDS
ANSI / ISA S84.01, Safety Instrumented Systems, Burner Management Systems, Safety Integrity Level,
Probability of Failure on Demand
ABSTRACT
This paper will discuss how quantitative methods can be utilized to select the appropriate Safety
Integrity Level associated with Burner Management Systems. Identifying the required amount of risk
reduction is extremely important especially when evaluating existing legacy Burner Management
Systems. Selection of an overly conservative Safety Integrity Level can have significant cost impacts.
These costs will either be associated with increased Safety Instrumented System functional testing or
complete removal / upgrade of the existing Burner Management System. In today’s highly competitive
business environment, unnecessary costs of any kind cannot be tolerated.
INTRODUCTION
Burner Management Systems have been typically designed in the past through applying the prescriptive
requirements contained in codes / standards such as NFPA 85 – Boiler and Combustion Systems Hazard
Code or API 556 – Instrumentation and Control Systems for Fired Heaters and Steam Generators.
These documents provide detailed guidance on the quantity and types of sensors / valves required for the
Burner Management System along with the logic necessary to safely trip the unit. These codes /
standards do not adequately address different risk levels associated with a Burner Management System.
For instance, if your boiler was located next to a control room, which was staffed 24-hrs/day risk to
personnel, is significantly greater than if it was located in a remote unoccupied area of the facility. In
addition, these prescriptive standards provide minimal guidance regarding the use of programmable
electronic based logic solvers.
New performance-based standards are now being utilized (i.e. IEC 61508, IEC 61511 and ANSI/ISA
S84.01) to design safety systems in general. These standards provide a set of criteria that must be met
2. 2
depending upon the amount of risk reduction required as determined by the end user. Thus, these
standards are specifically written to address the risks associated with a given facility. Therefore, these
standards when properly applied provide a wealth of information regarding the proper use and design of
a programmable electronic based logic solver in a safety application. Thus, when evaluating a Burner
Management System both the prescriptive codes / standards (NFPA, API) and the performance based
standards (IEC, ANSI/ISA) should be followed to ensure the Burner Management System is properly
designed and reduces a facilities risk to a tolerable level.
A furnace explosion requires both a sufficient flammable mixture and sufficient energy for ignition
within the furnace. The ignition requirements for an explosive charge are very small, making it almost
impossible to protect against all possible sources of ignition, such as static electricity discharges, hot
slag, and hot furnace surfaces. Therefore, the practical means of avoiding a furnace explosion is the
prevention of an explosive accumulation. The explosive accumulation is formed in the following basic
ways:
• A flammable input into any furnace atmosphere (loss of ignition)
• A fuel-rich input into an air-rich atmosphere (fuel interruption)
• An air-rich input into an fuel-rich atmosphere (air interruption)
The specific safety interlocking depends upon the physical characteristics of the firing system and the
type of fuel or fuels being fired. All Burner Management Systems, however are typically concerned
with the following functions:
• A pre-firing purge of the furnace.
• Establishment of the appropriate permissives for firing the ignition fuel (i.e. purge complete,
fuel pressure within limits).
• Establishment of the appropriate permissives, including ignition permissives, for the main (load-
carrying) fuel.
• Continuous monitoring of the firing conditions and other key operating parameters.
• Emergency shutdown of portions or all of the firing equipment when required.
• A post-firing purge.
CONSEQUENCE & LIKELIHOOD ESTIMATION
Effective consequence and likelihood estimation are critical components in the Safety Integrity Level
selection process. If the consequence estimation is too severe or the likelihood too aggressive the final
selected Safety Integrity Level may be too high, which will result in an over designed and very costly
Safety Instrumented System. While this approach is conservative, in today’s highly competitive
business environment facilities cannot afford to over design their safety systems if they desire to remain
in operation. Conversely, if the consequence estimation is too low or the likelihood too lax, the
facility’s risks may not have been adequately reduced by the Safety Instrumented System. In fact the
Safety Integrity Level selection process may not have required a Safety Instrumented System at all
depending upon the consequence, likelihood and layers of protection considered. In this scenario, the
company is operating beyond its risk threshold with an increased danger to personnel, the environment
3. 3
and / or their capital investments. Once again in a competitive business environment, this is an
unacceptable position for a facility.
Thus, accurate estimation the consequence and likelihood of a Burner Management System failure is
critical to determining the required Safety Integrity Level, which in turn determines the design
requirements for the Burner Management System.
CALCULATION OF SAFETY INTEGRITY LEVEL
To determine the consequence associated with fired equipment one will need to evaluate some or all of
the following effect zones. An effect zone is defined as the area over which a particular incident
outcome case produces an effect based upon a specified criterion (i.e. overpressure).
• Vapor Cloud Explosion Effect Zone
• Physical Explosion Effect Zone
• Pool Fire Effect Zone (liquid fuels only)
Calculation of the above effect zones can be quite complex and labor intensive. However, the
Environmental Protection Agency has developed simplified protocols for Risk Management Planning.
These protocols utilize equivalent TNT methodologies as contained in the Federal Emergency
Management Agency, Handbook of Chemical Analysis Procedures. These scenarios reflect a “worst
case scenario”which will yield conservative results that can be readily utilized in the Safety Integrity
Level selection process.
SEVEN STEP METHOD
These “worst case scenario”techniques can be simplified in a seven step method to yield required Safety
Integrity Levels.
STEP 1: Vapor Cloud Explosion Effect Zone can be calculated as follows:
1. Determine the maximum flammable mass that could be present in combustion chamber
2. Determine the heat of combustion for the flammable material (use la Chatelier’s Principle for
Mixtures if required)
3. Calculate the equivalent weight of TNT per the following equation:
Where,
mTNT is the equivalent weight of TNT, lbs.
mflammable is the flammable mass, lbs.
mTNT = [mflammable x ∆Hc x Yf ] Equation 1
1155
4. 4
∆Hc is the heat of combustion, kcal/kg.
1155 is the heat of combustion of TNT.
Yf is the explosive yield factor, which EPA has defined as 10%.
4. Calculate the radius for the circular impact zone per the following equation:
Where,
d is the distance to a given overpressure, ft.
O
p is the peak overpressure, psi, which is typically three (3) psi for calculation of fatalities.
5. Calculate the Vapor Cloud Explosion Effect Zone per the following equation:
Where,
VCEEffectZone is the Vapor Cloud Explosion Effect Zone, ft2
.
d is the distance to a given overpressure, ft.
STEP 2: Physical Explosion Effect Zone can be calculated as follows:
1. Determine the vessel rupture pressure, psia
2. Convert pressure in vessel to equivalent weight of TNT per the following equation:
Where,
mTNT is the equivalent weight of TNT, lbs.
P is the bursting pressure of the vessel, psia.
V is the volume of the vessel, ft3
.
3. Calculate the radius for the circular impact zone per the following equation:
Where,
d is the distance to a given overpressure, ft.
O
p is the peak overpressure, psi, which is typically three (3) psi for calculation of fatalities.
4. Calculate the Physical Explosion Effect Zone per the following equation:
d(ft) = mTNT
1/3
e3.5031-0.724ln(O
p)+0.0398(lnO
p)2
Equation 2
VCEEffectZone = πx d2
Equation 3
mTNT = 9.25x10-5
x P x V x ln( P ) Equation 4
14.7
d(ft) = mTNT
1/3
e3.5031-0.724ln(O
p)+0.0398(lnO
p)2
Equation 5
5. 5
Where,
PEEffectZone is the Physical Explosion Effect Zone, ft2
.
d is the distance to a given overpressure, ft.
STEP 3: Pool Fire Effect Zone (for liquid fuels only) can be calculated as follows:
1. Determine the area of the flammable pool. If the area is confined, use the confinement area. If
not calculate the area for a 1-cm deep pool per the following equation:
Where,
APool is the flammable pool area, ft2
.
d is the distance to a given overpressure, ft.
2. Calculate the Pool Fire Factor as follows for liquids with boiling points above ambient
temperature:
Calculate the Pool Fire Factor as follows for liquids with boiling points below ambient
temperature:
PEEffectZone = πx d2
Equation 6
APool = πx d2
Equation 7
PFF = Hc x 0.0001 -0.5
Equation 8A
5000 x πx (Hv + Cp x (Tb – 298))
where
Hc is the heat of combustion, J/Kg.
Hv is the heat of vaporization, J/Kg.
Cp is liquid heat capacity, J/Kg-K°.
Tb is the Boiling Temperature, K°.
PFF = Hc x 0.0001 -0.5
Equation 8B
5000 x πx Hv
where
Hc is the heat of combustion, J/Kg.
Hv is the heat of vaporization, J/Kg.
Cp is liquid heat capacity, J/Kg-K°.
Tb is the Boiling Temperature, K°.
6. 6
3. Calculate the radius for the circular impact zone per the following equation:
Where,
d is the distance to endpoint, ft.
R is the radiation intensity endpoint, kW/m2
, which shall be 12.5 kW//m2
for calculation of
fatalities.
PFF is the Pool Fire Factor.
A is the area of the pool, ft2
.
5. Calculate the Pool Fire Effect Zone per the following equation:
Where,
PFEffectZone is the Pool Fire Effect Zone, ft2
.
d is the distance to a radiation endpoint, ft.
STEP 4: Personnel Density can be calculated as follows:
1. Utilize the largest of the areas calculated in STEPS 1- 3 above. Overlay the effect zone on a
General Arrangement Drawing.
2. Calculate the number of Personnel / ft2
in the effect zone.
3. Calculate the Probable Loss of Life per the following equation:
Where,
MEZArea is Maximum Effect Zone Area, ft2
.
V is the Vulnerability Factor, where 0.6 is typically used if the effect zone is indoors and 0.3 is
typically used if the effect zone is outdoors.
P is the personnel density, people/ft2
.
PLL is Probable Loss of Life (i.e. number of fatalities in the effect zone).
STEP 5: Perform a Layer of Protection Analysis to determine the frequency for each hazardous event,
FLOPA. Note outcome frequencies should be added together for the same consequence (i.e. vapor cloud
explosion). Refer to CCPS “Layer of Protection Analysis, Simplified Process Risk Assessment”for
additional details on performing Layer of Protection Analysis.
STEP 6: Determine the Probability of Failure on Demand as follows:
d(ft) = 70.71 x ( 1 ) -0.5
x PFF x (A) -0.5
Equation 9
R x 1000
PFEffectZone = πx d2
Equation 10
PLL = MEZArea x V x P Equation 11
7. 7
1. Determine the Frequency Target per the following equation:
Where,
FTarget is the risk target, failure/year.
FIndividualRisk individual risk target, failure/year.
PLL is Probable Loss of Life (i.e. number of fatalities in the effect zone).
2. Calculate the Probability of Failure on Demand per the following equation:
Where,
PFD is Probability of Failure of Demand.
FTarget is the risk target, failure/year.
FLOPA is the frequency of the event per the Layer of Protection Analysis, failure/year.
STEP 7: Determine the require Safety Integrity Level as follows:
Where,
RRF is Risk Reduction Factor.
PFD is Probability of Failure of Demand.
SIL is then determined by the following:
SIL 1 = 10 < RRF < 100
SIL 2 = 100 < RRF < 1000
SIL 2 = 1000 < RRF < 10000
COMPANY STANDARD CALCULATIONS
Any Safety Integrity Level selection method adopted by a company needs to be easy to use and yield
results quickly. A labor intensive and time-consuming Safety Integrity Level selection method will
surely be abandoned when companies attempt to apply the method to the hundreds or thousands of
Safety Instrumented Function evaluations that they will need to perform. Thus, to make the Seven Step
procedure described above easier to utilize, it is recommended that companies develop a “cookbook
approach”that standardizes the types of fuels utilized in the company in following manner:
FTarget = FIndividualRisk Equation 12
PLL
PFD = FTarget Equation 13
FLOPA
RRF = 1 Equation 14
PFD
8. 8
1. Develop a spreadsheet application for each type of most common types of fuels the company
utilizes in their fired equipment to calculate each of the three (3) the effect zones.
2. Develop a supporting procedure on calculation of personnel densities.
3. Develop a spreadsheet application that provides a framework for Layer of Protection Analysis
for each of the standard Safety Instrumented Functions for Burner Management Systems.
4. Develop a supporting procedure to include guidance on how to perform a Layer of Protection
Analysis. This procedure should include lookup tables and guidance verbiage on how to
determine frequencies of initiating events for the Layer of Protection Analysis.
5. Develop a Cost – Benefit Analysis spreadsheet application to support justification of the project.
If such a company procedure were developed, then it would allow multiple remote plant sites to quickly,
efficiently and consistently evaluate Safety Integrity Level requirements for their Burner Management
Systems. This would allow facilities to make sound business decisions regarding the risks associated
with their fired equipment.
SAMPLE CALCULATIONS
The following sample calculation shall be performed for a single Safety Instrumented Function for a
Burner Management System to document the ease in which one can calculate the required Safety
Integrity Level.
Process Background: A commodity chemical company desires to determine the Safety Integrity Level
requirements for their existing single burner, natural gas (85% Methane, 15% Ethane) fired boiler. The
boiler was installed in 1985 and utilizes a general purpose PLC as the logic solver for the Burner
Management System. The boiler is operating efficiently and the company does not want to upgrade the
Burner Management System at this time due to capital cash constraints unless required. Therefore,
management wants an evaluation to be performed to determine if they are operating within their
tolerable risk limits. A small control room is located forty (40) feet from the boiler front. One (1) boiler
operator is present in this control room eighteen (18) hours a day on average. The control room is
general-purpose construction and not designed to withstand an explosion. Maintenance technicians are
present in the Boiler area 20% of the time. The boiler has a combustion chamber volume of 40,000 ft3
.
The boiler maximum operating pressure is 250 psig and it is estimated its burst pressure is four (4) times
the maximum operating pressure. The volume of the steam drum is 10,000 ft3
. A General Arrangement
Drawing review produced an area of 10,000 ft2 for the boiler building. The boiler typically operates for
fifty-one (51) weeks out of the year for twenty-four (24) hours per day.
Hazard: Low fuel gas pressure causes loss of flame and accumulation of unburned natural gas mixture,
which may explode if ignited.
Sensors: Fuel gas low pressure switch and loss of flame sensor.
Final Elements: Double Block and Bleed valves on the natural gas fuel and pilot supply lines.
9. 9
STEP 1: Vapor Cloud Explosion Effect Zone
STEP 2: Physical Explosion Effect Zone (Not required for this Safety Instrumented Function)
STEP 3: Pool Fire Effect Zone – Not Required for Natural Gas
STEP 4: Personnel Density
mTNT = [mflammable x ∆Hc x Yf ]
1155
mTNT = [165 lbs x 11859/1155 x 0.10]
mTNT = 169 lbs
d(ft) = mTNT
1/3
e3.5031-0.724ln(O
p)+0.0398(lnO
p)2
d(ft) = 1691/3
e3.5031-0.724ln(3.0)+0.0398(ln3.0)2
d(ft) = 87 ft
VCEEffectZone = πx d2
VCEEffectZone = 23,808 ft2
PLL = MEZArea x V x P
PLL = 23,808 x 0.6 x (1 x 18/24 + 1 x 4.8/24)/10,000
PLL = 1.357
10. 10
STEP 5: Layer of Protection Analysis
Initiating Event Protection Layer #1 Protection Layer #2 Outcome
Line Plugging Probability of Ignition Use Factor
1.96E-03 Explosion
/yr
0.98
0.8
2.50E-03 /yr
No event
STEP 6: Probability of Failure on Demand
STEP 7: Determine the require Safety Integrity Level
FTarget = FIndividualRisk
PLL
FTarget = 1 x 10-4
1.357
FTarget = 7.37 x 10-5
/ yr
PFD = FTarget
FLOPA
PFD = 7.37 x 10-5
1.96 x 10-3
PFD = 3.76 x 10-2
RRF = 1/PFD
RRF = 1/3.76 x 10-2
RRF = 27
Where 10 < RRF < 100 is SIL 1.
11. 11
Thus, the above low fuel pressure Safety Instrumented Function needs to be designed as a SIL 1
interlock with a RRF of at least 27. This information could then be utilized to evaluate the existing
Burner Management System to see if it meets the required SIL or needs to be re-designed.
Table 1
A summary of SIL calculations for a general purpose PLC with a one-year test interval are depicted
above. As can be seen for this particular Safety Instrumented Function, the existing Burner
Management System architecture is sufficient to meet the requirement of SIL 1 with a RRF of at least
27. Thus, the existing design is acceptable as is and will simply need to be functionally tested on an
annual basis.
CONCLUSION
Quantitative Risk Analysis methods can be complex and time consuming. However, using the
simplified “worst-case”scenario concepts contained in the EPA’s Risk Management Program Guidance
for Offsite Consequence Analysis one can quickly, efficiently and accurately determine Safety Integrity
Level requirements for Burner Management Systems. Accurate Safety Integrity Level selection is
critical when analyzing existing systems. If one is overly conservative, the resultant Safety Integrity
Level may require removal and upgrade of the existing Burner Management System. In today’s highly
competitive business environment, unnecessary costs of any kind cannot be tolerated.
DISCLAIMER
Although it is believed that the information in this paper is factual, no warranty or representation,
expressed or implied, is made with respect to any or all of the content thereof, and no legal responsibility
is assumed therefore. The examples shown are simply for illustration, and as such do not necessarily
represent any company’s guidelines. The readers should use data, methodology, formulas, and
guidelines that are appropriate for their situations.
12. 12
REFERENCES
1. ANSI/ISA S84.01-1996, Application of Safety Instrumented Systems for the Process Industries, The
Instrumentation, Systems, and Automation Society, Research Triangle Park, NC, 1996.
2. IEC 61508, Functional Safety of Electrical/Electronic/Programmable Safety-related Systems, Part
1-7,Geneva: International Electrotechnical Commission, 1998.
3. IEC d61511, Functional Safety: Safety Instrumented Systems for the Process Industry Sector, Parts
1-3, Geneva: International Electrotechnical Commission, Draft in Progress.
4. EPA, Risk Management Program Guidance for Offsite Consequence Analysis, Chemical Emergency
Preparedness and Prevention Office,1999
5. Lees, F.P., Loss Prevention in the Process Industries, Butterworth-Heinmann, 2nd
Edition, 2001
6. Singer, J.G., P.E., Combustion Fossil Power, Combustion Engineering, Inc., 1991
7. Center for Chemical Process Safety (CCPS), Layer of Protection Analysis, Simplified Process Risk
Assessment, American Institute of Chemical Engineers, New York, NY 2001.
8. FEMA, Handbook of Chemical Hazard Analysis Procedures