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1、2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,1,Introduction to E&I Safety Instrumented Systems(SIS)电仪安全仪表系统(SIS)介绍,2004-04-28Ulrich Schuenemann BYC NanjingBYC 南京尤瑞奇 舒曼CTA DepartmentE&I maintenance EOEG电仪维修EOEG CTA部,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,2,Control loops 控制回路
2、 DCS Monitoring functions 检测功能DCSInterlocks needed for smooth operation DCS,(ESD)顺利运行所需的连锁Interlocks related to plant Safety ESD与装置安全有关的连锁,There are different E&I functions 电仪功能各不相同,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,3,What are E&I S.I.S.什么是电仪S.I.S?,E&I Safety Instrumented System
3、s(S.I.S.):电仪安全仪表系统S.I.S.prevent 安全仪表系统用于防止：personnel injury 人身伤害或 environmental damage 环境破坏caused by a not tolerable fault state of the plant 由装置的不可接受的故障所造成 S.I.S.are defined in the Safety Review Step 2.安全仪表系统是在安全风险评估的第二步中定义的,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,4,Classification of
4、 E&I functions 电仪功能的分类,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,5,Definition of SIS:Safety Review step 2SIS的定义:安全审查步骤2,SEVERITY 严重性S1 Potential for one or more fatalitiesS2 Potential for one or more serious injuries(irreversible)S3 Potential for one or more lost time injuriesS4 Potenti
5、al for minor injuries,or irritationE&I SIS can be used for“risk class B and C”.电仪SIS可用于“B级和C级风险”,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,6,Example:E&I Safety Review 2 Checklist实例:电仪安全审查2检查清单,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,7,Failures of a S.I.S.的故障,Active errort
6、riggers off the safety function for no reasonplant is switched back to safe operationreduction of production availability有源故障-无缘无故触发安全功能-装置切回到安全运行-生产运行可用率降低,Passive error 无源故障inhibits the required safety function plant continues operation although it should be switched offimpacting the process safet
7、y,adversely affecting the safety function 对安全功能产生不利影响,no adverse effect onthe safety function对安全功能无不利影响,Failure 故障,Time-averaged probability for a passive fault:PFD“Probability of Failure on Demand”无源故障的时间平均可能性:PFD”指令故障的可能性“,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,8,Components of a SI
8、S SIS的组分,Shut-Down System 停车系统Logic in Failsafe PLC or Hardwired system在故障安全型可编程控制器或硬接线系统中的逻辑,Redundant sensors冗余的传感器,Valve阀门,Solenoid valve电磁阀,Instrument air supply 仪表气源,Rack Room 机柜间,Field 现场,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,9,Passive Faults of sensors and actuators传感器和致动器的无源
9、故障,mass flow meter after pressure pulse压力脉冲下游的质量流量计,lost control valve plug,control valve plug,damaged by cavitation,restriction orifice,deformed by flow,限流孔板,限流孔,限流孔板,流量造成的变形,调节阀阀塞,空穴造成的损坏,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,10,Some mathematics 一些算法,TITest Interval between functi
10、onal tests of SIS,time needed to discover dangerous faults SIS功能测试之间的时间间隔,发现危险故障需要的时间MTBFMean Time Between Failure of an equipment 设备故障之间的平均时间l=1/MTBFfailure rate 故障率Pf(t)Probability of failure(to function).For constantfailure rates l:Pf(t)=(1 e-l t)故障概率(对功能而言).恒定故障率 l:Pf(t)=(1 e-l t)PFDProbability
11、of Failure on Demand=Pf(t),time averaged over test interval TI 指令故障概率=Pf(t),时间间隔TI的平均时间 PFD=1/TI 0TI Pf(t)dt,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,11,PFD Probability of Failure on DemandPFD指令故障概率,Probability Pf(t)for finding equipment in dangerous fault state after time t has passed
12、 since last functional test自上次功能试验以来经过时间 t 后,发现设备处在危险故障状态的概率.,Pf(t)=(1 e-l t),time average 时间平均值,PFD Probability of Failure on demandPFD指令故障概率,PFD depends on failure rate of equipment AND test interval.PFD取决于设备AND试验间隔的故障率,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,12,Calculation of PFD P
13、FD的计算,PFD calculation of an individual equipment easy,if you havetest interval failure rate(given by supplier)如有试验间隔和故障率(供货方提供),则某个设备的PFD计算就不难PFD-calculation for more complex configurations(2oo3 etc.)can be done using simple statistical models:Good for comparing different configurations.用简单的统计模型可进行较
14、复杂的配置(2003等)的PFD计算For SIS:PFD of field domain and control domain must be added.对于SIS:必须加上磁场域和控制域的PFD PFDSIS=PFDsensor+PFDPLC+PFDactuator,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,13,Calculation of PFD the problemsPFD的计算问题,PFD data for field instruments usually not very reliable(not expe
15、rimentally verified for chemical environment).用于现场仪表的PFD数据通常不是很可靠(对于化学环境未经试验验证).Contribution to Failure Probability(PFD):对故障概率的影响因素calculated values for PFD:often not very accurate.PFD计算值:经常不太准,Field Instruments85%现场仪表,Logic Solver(failsafe PLC)15%逻辑解答器(故障保护PLC),2004-04-28 U.Schuenemann,Commissionin
16、g test of E&I SIS,14,“SIL”requirements for SIS SIS的“SIL”要求,For SIS:international and BASF standards request SIL 2 or SIL 3.对于SIS:国际标准和巴斯夫标准要求SIL2 或 SIL3.,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,15,How to meet“SIL”requirements 如何满足“SIL”要求,Right Instruments:from BASF standard list(field
17、 proven)or certified 仪表正确:来自巴斯夫标准清单或核准者(SIL 2,TUV certificate,)Devices without systematic design or manufacturing errors which can lead to common failure of redundant channels at the same time.2.Right Design:Redundancy,Diversity.Use design typicals in BASF standard.设计正确:冗余,多样性.采用巴斯夫标准中的典型设计 Redundan
18、t(and diverse)channels of sensors and actuators make system tolerant against single passive and active faults.3.Testing,Maintenance:perform commissioning test and periodic functional proof tests of SIS.测试,维护:进行SIS调试试验和定期的功能验证试验 In order to discover passive faults of SIS.Test interval depends on desi
19、gn.,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,16,BASF Global Standard Lists 巴斯夫全球标准清单,BASFs Standard Deviceshave passed extensive laboratory testing acc.to IEC770 at BASF,Ludwigshafen.are field-proven in non-safety related applications.have shown no passive fault during field testing(at
20、 least 10 devices monitored for 1 year).巴斯夫的标准装置已通过广泛的实验室试验,符合路德维希港巴斯夫IEC770标准.在相关危险应用中经过现场验证.在现场测试中未出现无源故障(至少10台装置被检测了一年).,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,17,Design:Typicals for SIL2 and SIL3 设计:SIL2 和 SIL3的典型之处,SIL2:single channel design 1oo1can be used12 month test interval
21、可使用单信道设计1oo112个月的试验间隔,SIL3:single channel design not allowed at least:2 sensors(1oo2)and 2 actuators.12 month test interval.不允许单信道设计至少2个传感器(1oo2)和2个致动器12个月的试验间隔,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,18,PFD of different Architectures 不同结构的PFD,Whats the best configuration:1oo1,1oo2,2o
22、o2,2oo3,2oo4,?最佳组态是什么?Consider:“failure on demand”-rate(affects plant safety)“false trip”-rate(affects plant availability)须考虑:“指令故障”率(影响装置安全)“误跳闸”率(影响装置可用率),plant safety 装置安全率,plant availability 装置可用率,Higher高,Lower低,2oo2,2oo2/2oo4,1oo1,2oo3,1oo3,1oo2/2oo4,2oo3,1oo3,1oo2,1oo1,2004-04-28 U.Schuenemann
23、,Commissioning test of E&I SIS,19,Commissioning&Proof Testing of E&I S.I.S.安全仪表系统的调试及试验,All International and BASF standards for SIS require a documented tests所有有关的国际标准或BASF标准均要求对安全仪表系统进行有文档记录的测试periodic proof tests 周期性的试验commissioning test before startup 开车前的调试,Objective for Commissioning Test:调试的目
24、的是为了检查：design according to Safety Review 2 设计遵照安全风险评估第二步所要求installation ok 安装正确parameter settings ok 参数设置无误function of instruments(sensors and actuators)ok 仪表功能（传感器,执行器）均正确无误logic action correct 逻辑动作正确,Commissioning test of S.I.S.will be main task for CTA PM during commissioning of plants.在装置调试期间，安全
25、仪表系统的调试是电仪经理的主要任务,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,20,Responsibilities for Commissioning Test调试试验的责任,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,21,CTA procedure for SIS Commissioning TestSIS调试试验的CTA程序,Status:状态Draft of CTA procedure completed CTA测试步骤草案已完成“Commission
26、ing and Periodic Proof Test of E&I SIS”安全仪表系统的调试及周期性试验how to perform commissioning test and periodic proof test 如何进行调试及周期性试验sample test procedures and check forms 取样测试步骤及检查表格definition of responsibilities between PM,Project team,Operation department 关于装置维护组，项目组、运行部门的职责的定义,2004-04-28 U.Schuenemann,Co
27、mmissioning test of E&I SIS,22,Labeling of SIS SIS的标签,SIS and their components(transmitter,power supply,I/O card of a logic solver)shall be clearly markedin the documentation(Z)in the field(Z)SIS及其组分(变送器,电源,逻辑解答器的I/O插件)在文件和现场(Z)中均清楚地加以标出.,2004-04-28 U.Schuenemann,Commissioning test of E&I SIS,23,Thank you for your attention,DANKE,
