© 2010 invensys. all rights reserved. the names, logos...

© 2010 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners.

© Invensys 00/00/00 Invensys proprietary & confidential Slide 2

Sustainable Safety Excellence “Making the right decision”

How do I know my plant is safe?

• Asset owner

• Plant management

• Plant employee

How does plant safety compare…

• Across plants?

• Across regions?

How Safe is My Process Plant?

Process incidents are expensive

• Loss of life

• Asset loss

• Revenue loss

• Loss of brand equity

• Increase regulatory scrutiny

• Possible jail time

Focus is often Occupational Safety

• Reducing slips, trips, falls

• Protection using hard-hats, etc.

Accidents Can Result From Lack of Safety Management

Process safety management is

often addressed after accidents!

Deepwater

Horizon

Texas City

Piper Alpha

Flixborough

Buncefield

Bhopal

Operations and

Maintenance

Slide 5

Maximizing Profit with Safety and Environmental Sustainability

Profit

Cost

Executives and

Management

Safety

Environment THE SAFETY GAP

Process Safety

Personnel Safety

85 serious releases

39% up from previous year

37 serious releases

48% up from previous year

Source ARC

Operational Continuity

Line of Equipment: Independent Layers of Protection

• Swiss Cheese Model

• Independent layers of

protection

• “Holes” are residual risks

• Hazard become accidents

when “holes” in LOPs line up

Accident

Hazard

Process

Design Other

DCS

SIS

Actual risk can increase over time

“Holes” can increase with insufficient safety management

Larger “hole” = increased risk of incident

Process Safety Management keeps risk at designed level

Continuous Management of Safety is Necessary

Commissioning + 20 years Operations

Example: Assume designed proof test interval (PTI) is 6 months

• Consider if proof testing is not performed after a few years

• Eventually SIL level is compromised!

Risk Can Increase Without Safety Management

9 Time

PFD

Lowest Risk

Unacceptable

Risk

Unsafe

Tolerable Risk

PTI PTI

Leading and lagging Indicators monitor quality of safety management

Key Performance Indicators Assess Quality of Safety Management

Process

Design Other

DCS

SIS

Key Performance

Indicators

Control Loop to Manage Plant (Operational) Risks

Key Performance

Indicators

Process Safety

Management

Process

Plant

Freedom from unacceptable risk due to:

• Fire

• Explosion

• Suffocation

• Poisoning

What is Process Safety Management (PSM)?

‘Keeping the Process in the Pipe’

Operational Integrity

Process Safety

Functional

Safety • DCS

• SIS

• AMS

Occupational

Safety • Trips

• Slips

• Falls

Operational Process Safety

• People

• Processes

• Equipment/Systems

Process Safety

Design

Risk

2

Business

Risk

1

Operational

Risk

3 GAP

OP

ER

AT

E &

MA

INTA

IN

DESIGN

RISK

OPERATION

AL RISK

BUSINESS

RISK

LOPA

SIL/SIF

SAFEGUARDS

SRS

SIMULATION

PERSONNEL

LOCATION

SKILLS &

COMPETENCIES

PROCEDURES

MOBILE

SOLUTIONS

DECISION SUPPORT

ASSET

MANAGEMENT

ALARMS

ONLINE SIL

DEMAND

RATES PROOF TESTS

INSTRUMENTATION

BPCS

SIS

INHIBIT / BYPASS MGT

EXECUTIVE DASHBOARD

HAZOP

SECURITY

PERFORMANCE REPORTS

SAFETY

RENDERING

Design

Risk

Safety Lifecycle Engineering Services

Slide 15

Functional Safety Lifecycle Services

•Structured and proven methodology to deliver consistent and measurable results

•Team of functional safety experts with deep domain knowledge

•HAZOP

• SIF Review and SIL Assignment

• Safety Requirement Specification (SRS) generation

•QRA – SIL Verification

• Professional development and accreditation (TÜV Certified Functional Safety Engineering Training)

SIL Tools - SilCore

• HAZOP Import

• SIL Determination (Risk Graph, LOPA or Safety Layer Matrix)

• SIF Optimization

• SIL Verification & Reliability Block Diagram

• Contingency Planning

• SI F Loop Failures

• Pre-stored Failure Rate Data

• Safety Requirement Specification (SRS) for SIF all in one database

• Automated Reports

Operational

Risk

Simulation

Slide 16

TRISIM Plus

•Virtual simulation of Triconex SIS controllers

•Base modelling capability of plant (DYNSIM)

•Validation and verification of application logic and changes

•Automated testing capability

•Repeat testing e.g. annual proof tests

DYNSIM

•Dynamic Process Simulation

•Increase plant safety by evaluating scenarios

•Evaluate plant start up and shut down procedures

•Test operation during abnormal events

EYESIM Virtual reality training system

•Immersive training environment

•Improve safety critical skills and competencies

•Increase overall effectiveness of personnel

•Train for high stress situations

Operational

Risk

Instrumentation

Slide 17

SIL2 Certified (TÜV) Pressure Transmitters

•>90% SFF (Safe Failure Fraction)

•Proof Test interval 1 or 2 years

•5 year warranty

•DD and DTM for configuration / diagnostics

SIL3 Certified Valve Positioners

•Intrinsically safe and explosion proof

•Manual / Automatic Partial Stroke Test (PST) for ESD Valves

•PST signature and complete PST report

•Available with HART, Profibus PA and Foundation Fieldbus (FF) H1

SIL/SIF

Operational

Risk

Basic Process Control System

Slide 18

Foxboro I/A

•NEW - Intelligent Marshalling

•NEW - Foxboro Control Software

•Continuously Current Philosophy – protects CAPEX

Foxboro PAC

•Programmable Automation Controller

•Scalable distributed control at PLC price

•Plant-wide integration made easy with Foxboro Control Software

3rd Party

•Integration through System Platform

•Application Server connectors

Operational

Risk

Safety Instrumented System

Slide 19

Emergency Shutdown Systems (ESD)

Burner Management Systems (BMS)

Fire and Gas Systems (F&G)

High Integrity Pressure Protection Systems

Triconex Tricon - TÜV Certified SIL3

• High availability – No single point of failure, online repair

• Integration with all DCS vendors equipment

• Comprehensive I/O modules range for all applications

• Large I/O Applications – local and distributed

Triconex Trident - TÜV Certified SIL3



• Ideal for Small – Medium I/O applications (up to 600 I/O per processor set)

• 1mS SOE on Digital Inputs – ideal for power applications

Triconex General Purpose System - TÜV Certified SIL2

• Low cost entry into the leading Triconex product line - breaks through the budget barriers



• Lowest total lifecycle cost compared to PLCs

Operational

Risk

Operational / Maintenance Risk

Slide 20

Safety View – Inhibit and Bypass Management

• View alarms by SIF

• Inhibit & Bypass Management

• Support Safety Workflow (per IEC 61511)

• Complies with ISA 18.1-2004 Annunciator Sequences and Specifications Standard

Alarm Management and Rationalisation

•Improve Safety

•Improve Overall Operator Effectiveness •Tools (PAS) and Services

Asset Management

• Equipment Integrity

• Manage Maintenance scheduling and backlog

• Condition Management of equipment

Operational

Risk

Personnel and activities

Slide 21

Mobile Workforce Solutions – IntelaTrac

•Safety rounds and inspections

•Workforce and decision support system

•Dynamic procedures triggered on asset condition

•Improved decisions and compliance

Process and Procedures – ArchestrA Workflow

•Digitize manual and automated procedures

•Drive standardisation and compliance

•Automatically Escalate as risk increases

•Measure and improve performance

Real-Time Personnel Location

•Track, manage, analyse and leverage personnel

•Hazard Detection – right people, right areas, right permits, right qualifications

•Preparedness – monitor and record drills, assess preparedness, spot gaps

•Emergency response - automatically account for all workers, guide find & rescue missions

Operational

Risk

Safety and Security

Slide 22

Safety Rendering

• Real time view of risk across plant

• Support priority / decision making

• Avoidance of high risk areas

Security Services

• Hardware independent, Defnese in Depth strategy

• Regulation knowledge and expertise

• Assessment, Design, Implementation, support

• Compliance with stringent standards such as Nuclear Regulatory Commission (NRC)

Security Built in

• Achilles Level 1certification

• Tofino firewall specifically for Triconex products

• S99 Compliance

Real-Time Profitable Safety

Slide 23

Business

Risk

Machu Picchu Decision Support

• Understand the risks present

• Understand the potential consequences (economic / safety / Environmental)

• Understand how to manage the risk

• Make the RIGHT decision

Process Safety Performance Management

• Process Safety Management dashboards

• Know how you are doing - PSM Key Performance Indicators

• Predict future impact - Leading indicators

• Demonstrate how you Continuously Improving

Profitable Safety Value Creation

• Measure – Real time risk / safety conditions

• Empower – Risk and Condition notification

• Improve - Constraint Level Variable Risk & Profitability

Safety

Culture

Operational

Safety

Practices

Functional

Safety

Management

Functional Safety Management

SafetyView

SafetyView CoSIL

Triconex EnDM

SafetyView Bypass Mgr

Tricon, Trident, Tri-GP, Tristation

Consulting, PAS

Foxboro Eckhardt

Alarms

Inhibits / Overrides

Diagnostic Information

Dynamic SIL / SIF Loop Performance

Proof Tests / Demand Rates

SIS H/W

Measurements and Instruments

Operational Safety Practices

Mobile Workforce

Risk Management and Decision Support

Asset and Condition Management

Equipment Models and Simulation

Operator / Maintenance Skills and Competencies

Procedures and Workflows

Personnel Location

Security

Safety / Risk Profile

Safety Reports

SimSci-Esscor

Avantis

Skelta

Intelletrac

SimSci-Esscor

Consulting

ACM MP Risk Exposure

SafetyView

SafetyView

SILCore TriDefine Workbench

Lifecycle Automation Tools

Control Loop to Manage Plant (Operational) Risks

Key Performance

Indicators

Process Safety

Management

Process

Plant

Tolerable risk level is maintained during operation phase

“Holes” sizes remain unchanged by monitoring feedback

Increase Confidence Using KPIs: Risk at Defined Level

26

Commissioning + 20 years Operations

Process Safety

Management

• Measure

• Empower

• Improve

Example : Periodic Proof Test

1. How many safety-related field devices were proof tested (periodic) in time (PTI)?

2. Do procedures exist and were they followed?

3. What is the number of competent & trained personnel performing the work?

Possible Safety Key Performance Indicators

Plant

Procedures People

Sources of KPIs include:

• ISA 84.00.04 – Recommended Practices for Guidelines for the

Implementation of ANSI/ISA-TR84.00.01-2004 (IEC 61511 Mod)

• CCPS (Centre for Chemical Process Safety)

• Energy Institute

• Others

Common Theme:

• People – leadership, competency, training

• Procedures – e.g., operational readiness reviews; safety audits

• Plant (equipment) – e.g., management of safety critical devices

KPI Sources

Corp

Plant

Equipment

Layer of Protection

Safety Performance Indicator

KPIs

SPIe, Asset Risk

SPIp, Asset Risk

Asset Risk

KPIs (plant, people,

procedures)

KPIs weighted

average

SPI for plant.

Inc. Asset at Risk

Inc. Value at Risk

(assets, revenue)

Single number for overall

plant risk

Unique ‘Value at Risk’ Metric

• Plant’s Safety Performance Indicator

• Incremental Asset Value at Risk & Production Value at Risk

• KPI metrics/trends

• Drill down to equipment level KPIs

Plant Dashboard for Process Safety Management

Corporate Dashboard for Process Safety Management

• Aggregate incremental values at risk for the corporation

• Plant Safety Performance Indicators for all plants / regions

• Drill down to plant dashboard

Step 1: Establish the organizational arrangements to implement indicators

Step 2: Decide on the scope of the indicators

Step 3: Identify the risk control systems and decide on the outcomes

Step 4: Identify critical elements of each risk control system

Step 5: Establish data collection and reporting system

Step 6: Review (benchmark against the IE PSM Framework or equivalent)

Step 7: Deploy KPI model and SPI calculations

Step 8: Establish management role and actions for review of KPI, SPI,

estimated asset-at-risk and estimated production-at-risk

Eight Steps to Safety Performance Measurement

Maximizing Profit with Safety and Environmental sustainability

“Can I make more profit?” Commercial Integrity Level

“Am I Environmentally Sustainable?” Environmental Integrity Level

“Am I safe enough?” Safety Integrity Level

Balance

Decision?

What’s Wrong? What’s the impact?

Fix the problem?

Category?

Commercial

Safety

Environmental

© 2010 invensys. all rights reserved. the names, logos...

Documents