TECHNICAL REPORT ISA-TR84.00.04-2005 Part 2 Example Implementation of ANSI/ISA-84.00.01-2004 (IEC 61511 Mod) Approved 1 December 2005 N OTICE OF COPYRIGHT --``,`,``,``,`,````,``,,`,,,`,`-`-`,,`,,`,`,,`--- This is a copyright document and may not be copied or distributed in any form or manner without the permission of ISA. This copy of the document was made for the sole use of the person to whom ISA provided it and is subject to the restrictions stated in ISA’s license to that person. It may not be provided to any other person in print, electronic, or any other form. Violations of ISA’s copyright will be prosecuted to the fullest extent of the law and may result in substantial civil and criminal penalties. Copyright International Society of Automation Provided by IHS under license with ISA Licensee=Fermilab Research Alliance LLC/5970717001 No reproduction or networking permitted without license from IHS Not for Resale, 05/07/2014 02:49:10 MDT ISA-TR84.00.04-2005 Part 2 -- Example Implementation of ANSI/ISA-84.00.01-2004 (IEC 61511 Mod) ISBN: 1-55617-980-4 Copyright © 2005 by ISA. All rights reserved. Not for resale. Printed in the United States of America. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means (electronic, mechanical, photocopying, recording, or otherwise), without the prior written permission of the Publisher. ISA 67 Alexander Drive P.O. Box 12277 Research Triangle Park, North Carolina 27709 --``,`,``,``,`,````,``,,`,,,`,`-`-`,,`,,`,`,,`--- Copyright International Society of Automation Provided by IHS under license with ISA Licensee=Fermilab Research Alliance LLC/5970717001 No reproduction or networking permitted without license from IHS Not for Resale, 05/07/2014 02:49:10 MDT - 3 - ISA-TR84.00.04-2005 Part 2 Preface This preface, as well as all footnotes and annexes, is included for information purposes and is not part of ISA-TR84.00.04-2005 Part 2. This document has been prepared as part of the service of ISA toward a goal of uniformity in the field of instrumentation. To be of real value, this document should not be static but should be subject to periodic review. Toward this end, the Society welcomes all comments and criticisms and asks that they be addressed to the Secretary, Standards and Practices Board; ISA; 67 Alexander Drive; P. O. Box 12277; Research Triangle Park, NC 27709; Telephone (919) 549-8411; Fax (919) 549-8288; E-mail: [email protected]. It is the policy of ISA to encourage and welcome the participation of all concerned individuals and interests in the development of ISA standards, recommended practices, and technical reports. Participation in the ISA standards-making process by an individual in no way constitutes endorsement by the employer of that individual, of ISA, or of any of the standards, recommended practices, and technical reports that ISA develops. CAUTION — ISA ADHERES TO THE POLICY OF THE AMERICAN NATIONAL STANDARDS INSTITUTE WITH REGARD TO PATENTS. IF ISA IS INFORMED OF AN EXISTING PATENT THAT IS REQUIRED FOR USE OF THE DOCUMENT, IT WILL REQUIRE THE OWNER OF THE PATENT TO EITHER GRANT A ROYALTY-FREE LICENSE FOR USE OF THE PATENT BY USERS COMPLYING WITH THE DOCUMENT OR A LICENSE ON REASONABLE TERMS AND CONDITIONS THAT ARE FREE FROM UNFAIR DISCRIMINATION. EVEN IF ISA IS UNAWARE OF ANY PATENT COVERING THIS DOCUMENT, THE USER IS CAUTIONED THAT IMPLEMENTATION OF THE DOCUMENT MAY REQUIRE USE OF TECHNIQUES, PROCESSES, OR MATERIALS COVERED BY PATENT RIGHTS. ISA TAKES NO POSITION ON THE EXISTENCE OR VALIDITY OF ANY PATENT RIGHTS THAT MAY BE INVOLVED IN IMPLEMENTING THE DOCUMENT. ISA IS NOT RESPONSIBLE FOR IDENTIFYING ALL PATENTS THAT MAY REQUIRE A LICENSE BEFORE IMPLEMENTATION OF THE DOCUMENT OR FOR INVESTIGATING THE VALIDITY OR SCOPE OF ANY PATENTS BROUGHT TO ITS ATTENTION. THE USER SHOULD CAREFULLY INVESTIGATE RELEVANT PATENTS BEFORE USING THE DOCUMENT FOR THE USER’S INTENDED APPLICATION. HOWEVER, ISA ASKS THAT ANYONE REVIEWING THIS DOCUMENT WHO IS AWARE OF ANY PATENTS THAT MAY IMPACT IMPLEMENTATION OF THE DOCUMENT NOTIFY THE ISA STANDARDS AND PRACTICES DEPARTMENT OF THE PATENT AND ITS OWNER. ADDITIONALLY, THE USE OF THIS DOCUMENT MAY INVOLVE HAZARDOUS MATERIALS, OPERATIONS OR EQUIPMENT. THE DOCUMENT CANNOT ANTICIPATE ALL POSSIBLE APPLICATIONS OR ADDRESS ALL POSSIBLE SAFETY ISSUES ASSOCIATED WITH USE IN HAZARDOUS CONDITIONS. THE USER OF THIS DOCUMENT MUST EXERCISE SOUND PROFESSIONAL JUDGMENT CONCERNING ITS USE AND APPLICABILITY UNDER THE USER’S PARTICULAR CIRCUMSTANCES. THE USER MUST ALSO CONSIDER THE APPLICABILITY OF ANY GOVERNMENTAL REGULATORY LIMITATIONS AND ESTABLISHED SAFETY AND HEALTH PRACTICES BEFORE IMPLEMENTING THIS DOCUMENT. THE USER OF THIS DOCUMENT SHOULD BE AWARE THAT THIS DOCUMENT MAY BE IMPACTED BY ELECTRONIC SECURITY ISSUES. THE COMMITTEE HAS NOT YET ADDRESSED THE POTENTIAL ISSUES IN THIS VERSION. Copyright International Soc iety of Automation Copyright 2005 ISA. All rights reserved. --``,`,``,``,`,````,``,,`,,,`,`-`-`,,`,,`,`,,`--- Provided by IHS under license with ISA Licensee=Fermilab Research Alliance LLC/5970717001 No reproduction or networking permitted without license from IHS Not for Resale, 05/07/2014 02:49:10 MDT ISA-TR84.00.04-2005 Part 2 — 4 — This ISA technical report was prepared by ISA-SP84 Working Group 2, which included the following members: NAME COMPANY A. Summers, ISA-SP84 WG2 Leader SIS-TECH Solutions LLC W. Johnson, ISA-SP84 Chair E.I. Du Pont V. Maggioli, ISA-SP84 Managing Director Feltronics Corp. R. Dunn, ISA-SP84 Recorder DuPont Engineering R. Adamski Premier Consulting Services H. Bezecny Dow Deutschland D. Bolland ExxonMobil Research & Engineering Co. K. Bond Consultant S. Brown Health & Safety Executive (HSE), UK NJWAKWDP...... . . CGDG GCCGaoraarooumewnmhbhedpeemlnnehblnl ,iye IlIl I CRKUEKRICBBxooOoSihnhRRdP ommTa cL r Coi&aLpPnoC lHedmh xa ilH laLipasLsa CC s o Cmop. any --``,`,``,``,`,````,``,,`,,,`,`-`-`,,`,,`,`,,`--- J. Harris UOP LLC W. Hearn Westinghouse Savannah River Co. T. Jackson Bechtel Corp. K. Klein Solutia, Inc. M. Lang CF Industries T. Layer Emerson Process Management N. McLeod Arkema E. Marszal Kenexis R. Nelson Celanese Corp. D. Novak BASF Corp. T. Ostrowski Oxychem W. Owen Chevron Research & Technology Co. G. Ramachandran Motiva Enterprises LLC G. Robertson Oxy Information Technology L. Robison BP Oil S. Shah Exxon Mobil Chemical Co. J. Siebert Invista B. Smith Nova Chemicals C. Sossman Washington Safety Management Solutions LLC P. Stavrianidis FM Approvals H. Storey Shell Global Solutions R. Strube Intertek Testing Services NA, Inc. L. Suttinger Westinghouse Savannah River Co. K. Szafron BP R. Szanyi ExxonMobil Research Engineering R. Taubert BASF Corp H. Thomas Air Products & Chemicals Inc A. Woltman Shell Global Solutions D. Zetterberg Chevron Energy Technology Co. Copyright 2005 ISA. All rights reserved. Copyright International Society of Automation Provided by IHS under license with ISA Licensee=Fermilab Research Alliance LLC/5970717001 No reproduction or networking permitted without license from IHS Not for Resale, 05/07/2014 02:49:10 MDT - 5 - ISA-TR84.00.04-2005 Part 2 This ISA technical report was approved for publication by the ISA Standards and Practices Board on 1 December 2005: NAME COMPANY I. Verhappen, President Syncrude Canada, Ltd. F. Amir E I Du Pont Co. D. Bishop Consultant M. Coppler Ametek Inc. B. Dumortier Schneider Electric W. Holland Consultant E. Icayan ACES Inc. A. Iverson Ivy Optiks R. Jones Consultant K. P. Lindner Endress + Hauser Process Solutions V. Maggioli Feltronics Corp. T. McAvinew Jacobs Engineering Group A. McCauley Chagrin Valley Controls Inc. G. McFarland Emerson Process Management R. Reimer Rockwell Automation J. Rennie Consultant N. Sands E I Du Pont Co. H. Sasajima Yamatake Corp. T. Schnaare Rosemount Inc. A. Summers SIS-TECH Solutions LLC J. Tatera Tatera & Associates R. Webb Consultant W. Weidman Parsons Energy and Chemicals J. Weiss KEMA Inc. M. Widmeyer Stanford Linear Accelerator Center C. Williams Eastman Kodak Co. M. Zielinski Emerson Process Management --``,`,``,``,`,````,``,,`,,,`,`C-`-`o,,`p,,y`,`r,,i`g--h- t 2005 ISA. All rights reserved. Copyright International Society of Automation Provided by IHS under license with ISA Licensee=Fermilab Research Alliance LLC/5970717001 No reproduction or networking permitted without license from IHS Not for Resale, 05/07/2014 02:49:10 MDT --``,`,``,``,`,````,``,,`,,,`,`-`-`,,`,,`,`,,`--- This page intentionally left blank. Copyright International Society of Automation Provided by IHS under license with ISA Licensee=Fermilab Research Alliance LLC/5970717001 No reproduction or networking permitted without license from IHS Not for Resale, 05/07/2014 02:49:10 MDT - 7 - ISA-TR84.00.04-2005 Part 2 CONTENTS 1 Introduction.........................................................................................................................................9 2 Project Definition................................................................................................................................9 2.1 Conceptual Planning...............................................................................................................10 2.2 Process Hazards Analysis......................................................................................................10 3 Simplified Process Description......................................................................................................10 4 Preliminary Design...........................................................................................................................12 5 ISA-84.01-2004 Application.............................................................................................................12 5.1 Step 1: Hazard & Risk Assessment.......................................................................................16 5.2 Step 2: Allocation of Safety Functions..................................................................................28 5.3 Step 3: SIS Safety Requirements Specifications..................................................................32 5.4 Step 4: SIS Design and Engineering......................................................................................52 5.5 Step 5: SIS Installation, Commissioning, Validation...........................................................63 5.6 Step 6: SIS Operation and Maintenance...............................................................................78 5.7 Step 7: SIS Modification.........................................................................................................80 5.8 Step 8: SIS Decommissioning................................................................................................81 5.9 Step 9: SIS Verification...........................................................................................................81 5.10 Step 10: Management of Functional Safety and SIS Functional Safety Assessment......82 --``,`,``,``,`,````,``,,`,,,`,`-`-`,,`,,`,`,,`--- Copyright 2005 ISA. All rights reserved. Copyright International Society of Automation Provided by IHS under license with ISA Licensee=Fermilab Research Alliance LLC/5970717001 No reproduction or networking permitted without license from IHS Not for Resale, 05/07/2014 02:49:10 MDT This page intentionally left blank. --``,`,``,``,`,````,``,,`,,,`,`-`-`,,`,,`,`,,`--- Copyright International Society of Automation Provided by IHS under license with ISA Licensee=Fermilab Research Alliance LLC/5970717001 No reproduction or networking permitted without license from IHS Not for Resale, 05/07/2014 02:49:10 MDT — 9 — ISA-TR84.00.04-2005 Part 2 NOTE — This example is used with permission from AIChE, CCPS, Guidelines for Safe Automation of Chemical Processes, New York, 1993, available from: AIChE, 345 East 47th Street, New York, NY 10017, Tel: (212) 705-7657; and Process Industry Practices (PIP), Safety Instrumented Systems Guidelines, available from: Process Industry Practices (PIP), 3925 West Braker Lane (R4500), Austin, TX 78759, Tel: (512) 232-3041, www.PIP.org. The example is modified to meet ANSI/ISA 84.00.01-2004 (IEC 61511 Mod) requirements. This example was chosen to facilitate understanding of SIS application as it progressed from CCPS Guidelines dated 1993 to ANSI/ISA S84.01-1996, to ANSI/ISA 84.00.00.01-2004 (IEC 61511 Mod). This example was also used in Appendix B of AIChE, CCPS, Layer of Protection Analysis, Simplified Process Risk Assessment, 2001. 1 Introduction Used in conjunction with ISA-TR84.00.04-2005 Part 1, the example set forth in this technical report is provided to illustrate how to apply ANSI/ISA-84.00.01-2004 Parts 1-3 (IEC 61511Mod). It is intended to demonstrate one method to meet the requirements of the standards. The reader should be aware that AcHlrm NaeaONAyeqnTeZSeu ErbtOiIs r /e—teI,PhS mf ue TaAts eheur-ernec8lotdthq 4ust nur.tg.0oe iih qr0 eOoeau. um0catethh1n setehi-a en2frilos vty0ts reest0 e hioc4scchafh o fPnztnomhaiiaqrcep rrauSd tllssie Iarta Lsea1nn p n-vcado3deenr arrt.(d,i iI rsf EtidSthkcoCse oaoa. mtt l6niesor1ae mnc5l y,oo 1“safuI1 Sintsl hdAdM, e - Lb8lo a4Oemd.d 0P)ued1 titA-esih2l ri 0ozfp o0ldeoe4rsdgr ”af ioaiaclslrp to mt upoecslaa aiedentcdiodo chtc oen iuon rbomf e taftfh eehssirnese at tsodfe eet ,xhA t aayseN tmn SfeaudIpp/pn ISstlpech Alit ainii-con8t a 4ntcmht.lsi0uoea 0dtn n.os0e ya 1s:p - ofa2wrefo0ptth0wytpea4 ral ctioPf-rteiaaeiforc c atnyshn c e1dls-e3 to --``,`,``,``,`,````,``,,`,,,`,`-`-`,,`,,`,`,,`--- (IEC 61511 Mod). The example utilizes the similar chemical process presented in AIChE CCPS, Guidelines for Safe Automation of Process Applications, 1993, and in PIP PCESS001 1999, Safety Instrumented Systems Guidelines. The safety lifecycle application in the CCPS version was based on the initial version of IEC 61508. The safety lifecycle application in the PIP version was based on ANSI/ISA-S84.01-1996. The safety lifecycle example herein is based on ISA-84.01-2004. As a result, the evolution of new design requirements can be assessed by comparing this example with previous versions. This example selects a subsystem of a process and applies to it the design philosophy, procedures, techniques, and verification methodology discussed in ISA-84.01-2004. This example shows cradle-to-grave documentation for each SIF. This documentation pedigree gives auditors and plant personnel the means to track the SIF through the safety lifecycle phases back to the process hazards analysis (PHA) that created it. Each SIF is clearly identified in each document to facilitate tracking between lifecycle phases. A vital part of safety is the ability to demonstrate to others (e.g., auditors, regulators, insurance companies) that the risk reduction provided by each SIF is adequate. This example does not represent a complete design for a polymerization process because of the extensive detail that is required to achieve a high-integrity, safely automated design. As a result, this example includes a number of simplifications. All references shown refer to information within this example unless otherwise noted. 2 Project Definition The process is the polymerization of vinyl chloride monomer (VCM), CH =CHCl 2 to make polyvinyl chloride (PVC), [−CH −CHCl−] 2 n Copyright 2005 ISA. All rights reserved. Copyright International Society of Automation Provided by IHS under license with ISA Licensee=Fermilab Research Alliance LLC/5970717001 No reproduction or networking permitted without license from IHS Not for Resale, 05/07/2014 02:49:10 MDT ISA-TR84.00.04-2005 Part 2 — 10 — The example involves a hazardous reactant, VCM, which is flammable and has toxic combustion products, as well as being a known carcinogen. The process also illustrates a larger-scale batch operation that operates in a semi-continuous manner during an approximately 10-hour period while the polymerization progresses. A simplified description of the process steps is also provided. 2.1 Conceptual Planning Once a business decision is made to consider producing a certain product–in this example, polyvinyl chloride–the initial project team is assembled. This team will start by evaluating potential process routes to identify a technology that will satisfy production needs while meeting responsibilities for health, safety, and protection of the environment. 2.2 Process Hazards Analysis In the very early stages of process evaluation and project definition, a process hazards analysis team (in this example, P.H.A. Smith, Process Jones, S. Bulk, V. May, R. Brown, W. Burk, A.C. Green) starts to interact closely with the designers. For projects handling hazardous materials, the team will include not only process design engineers but also health and safety specialists. The team will often need to have access to other specialists–such as chemists, operating personnel, consultants or engineering contractors having experience with the same or similar processes, and process licensors. In this example, a well-proven process is available as a starting point. Therefore, we will proceed with the business decision to produce this product, and concentrate on the aspects of the design process that influence or directly involve the design of the process control systems and safety interlock systems. More detailed information on related aspects of the design process can be found in the following list of texts from the Center for Chemical Process Safety, American Institute of Chemical Engineers: (cid:137) Guidelines for Hazard Evaluation Procedures (cid:137) Guidelines for Chemical Process Quantitative Risk Analysis (cid:137) Guidelines for Safe Storage and Handling of High Toxic Hazard Material (cid:137) Guidelines for Vapor Release Mitigation (cid:137) Guidelines for the Technical Management of Chemical Process Safety. 3 Simplified Process Description The manufacture of PVC from the monomer is relatively straightforward. The heart of the process is the reactor vessel in which the polymerization takes place over a period of about ten hours, while the reactor contents are agitated mechanically and the heat of reaction is removed by the circulation of cooling water through the reactor jacket. Because the process involves the charging of a batch to the reactor, process systems are designed with multiple reactor units in parallel, so that the process can operate on a semi- c porondtiuncutoiouns fbaacsiliitsy. wFoillr tsyipmicpalilclyit yh,a tvheis seexvaemrapl lep awrailll lefol cuunsit so no poenrea toinf gth ien usneiqtsu,e rnecceo.g nizing that a real --``,`,``,``,`,````,``,,`,,,`,`-`-`,,`,,`,`,,`--- Copyright 2005 ISA. All rights reserved. Copyright International Society of Automation Provided by IHS under license with ISA Licensee=Fermilab Research Alliance LLC/5970717001 No reproduction or networking permitted without license from IHS Not for Resale, 05/07/2014 02:49:10 MDT