ControlDraw Demonstration A Safety Shutdown System Model Print and Review Report

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Brooke Hunt
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1 ControlDraw A Safety Shutdown System Model Print and Review Report Thanks to Horizon Consulting for the original documents - only selected portions of the model are in this PDF ControlDraw Users Page: 1 of 1

2 Table of Contents Section Page Cover 1 Table of Contents List of Included Diagrams Diagrams Plant Overview 5 - Boiler Overview Boiler Startup Sequence Fault Tree Boiler Equipment Damage Boiler Event Trees 1 - Copy of Safire 1 Fault Tree 1 - Hardware Concept IO List connected to model Original Cause and Effect SIL Results 17 Data Reports: 18 Safety Control Functions 18 Alarm Set points 19 Control System IOList 0 ControlDraw Users Page: of 1

3 List of Included Diagrams Diagram Objs Class Vers Lastauthor Date 1 Plant Overview 7 Process Cell 107 Francis Lovering -Jan-05 Boiler Overview 68 Unit 108 Francis Lovering -Jan-05 4 Boiler Startup Sequence Phase 107 Francis Lovering -Jan Safety Control Function 1 Francis Lovering 08-Feb Safety Control Function 96 Francis Lovering -Jan Fault Tree 5 Control Module 11 Francis Lovering 0-Feb-05 0 Boiler Equipment Damage 1 Document Reference 10 Francis Lovering -Jan-05 1 Boiler Event Trees 5 Document Reference 10 Francis Lovering -Jan-05 Copy of Safire 1 Fault Tree None 111 Francis Lovering -Jan-05 Hardware Concept 15 None 109 Francis Lovering -Jan-05 4 IO List connected to model 1 None 108 Francis Lovering -Jan-05 5 Original Cause and Effect None 119 Francis Lovering 01-Feb-05 6 SIL Results None 97 Francis Lovering -Jan-05 ControlDraw Users Page: of 1

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5 Diagram 1 - Plant Overview Diagram Version: 107 Class: Process Cell Diagram 1 of 6 PageID: 7 This is the top level of the physical heirachy U6 Boiler overview graphic and Cause and Effect matrix Boiler Startup Sequence High Combustibles / Explosions Event Tree 1 Boiler Equipment Damage Event Tree 4 0 Example of using a Caption, Captions can be used, for example, for defining dialog text, and for translations Captions are text objects linked to a symbol, in this case U6. Simplified P&ID showing Causes, Effects and Matrix. All physical object data is rooted from this symbol Child Page Number Contains the number of the page linked to a symbol. Click the number, or double click a symbol to open the page. Procedural Model Root Object All procedural object data is rooted from this symbol Event Trees, with links to the Functions This model is under development. Please look at each diagram and especially the notes. (Use Ctrl_G to find all objects in the model) These objects are linked to diagrams in the model, for reference. They also prevent the pages being shown as orphaned in Model Review. They are class None and do nothing in the database. Original Cause and Effect 5 SIL Results IO List connected to model 4 Hardware Concept Original 1 Fault 1 Fault Tree This diagram is scripted to generate Tree 6 the probabilities from the tree. 6 Key Effect * Effect with link to logic 000 Cause with link to logic Thismodel covers a Safety Shutdown system only. It would be possible to also include the DCS, with some development of classes to distinguish the and DCS functions and hardware. ControlDraw Users Page: 5 of 1

6 Diagram - Boiler Overview Diagram Version: 108 Class: Unit Diagram of 6 PageID: 7 This diagram could be simplified by sub division into equipment modules, however as the process is fairly simple this has not been done. HS/blnOut1 Diagram 10 BSD Button 11 Control Room BSD Button See also 01 Fault Tree See also Original Cause and Effect UX- 605 Trident Common Trouble Alarm Cause/Effect Effect FC-0159 Effect XY-664 XY-666 Effect XY-665 Effect XY-667 XY-669 Effect XY-670 Effect XY-67 Effect XY XL- 016-S Boiler #1 S/D Lamp 04 Refinery Gas Effect FC-0159 Main Fuel Gas Control Valve Natural Gas Boiler Field startup panel Low Low Fuel Header Gas PT UX- 9 UX Boiler 1601 Fuel Gas Common S/D FC-0159 Main Fuel Gas Control Valve PT HS Control Room Common Enable Alarms to DCS Effect XY-667 XY-669 Main Fuel Gas Shutdown Valves PSL Description Main Fuel Gas Control Valve Pilot Gas Shutdown Valves Pilot GasVentValve Main Fuel Gas Shutdown Valves Oxygen Analyzer De-Energized Fan Interposing Lube Oil Aux. Pump Interposing Low Low Steam Drum Level High High Steam Drum Loss of Flame Low Low Fuel Header Gas Low Low Fuel Burner Gas High High Fuel Burner Gas Low Low Combustion Air Flow Low Low Pilot Gas Header High High Furnace BSD Button Control Room BSD Button Low Lube Oil Low Low Lube Oil Boiler 1601 Air Group Common S/D Pilot GasVentValve XV-664 Pilot Gas Shutdown Valve 9 Effect XY-665 Effect XY-664 XY-666 Pilot Gas Shutdown Valves Low Low Pilot Gas Header XL- 016-R Boiler #1 Run Lamp UX XV-667 Main Fuel Gas Shutdown Valve Vent XV-665 Pilot Gas Vent Valve See page Control Room BSD Button XV-669 Main Fuel Gas Shutdown Valve Effect XY-667 XY-669 PT / HS 5/ 5/ XV-666 Pilot Gas Shutdown Valve 5/ Effect FC-0159 X LSH 011 LSL Low Low Fuel Burner Gas High High Fuel Burner Gas Effect XY-664 XY-666 LSLL Effect XY-665 Open Open Open 1 High High Steam Drum PT BS- 018 BS Overall Cause and Effect Matrix Effect XY-670 Steam Drum UY Effect XY-675 Lube Oil Aux. Pump Interposing Effect XY-675 Start Start 09 Effect XY-67 Stop 01 High High Furnace Ignitor Transformer Interposing Low Low Steam Drum Level 8 Top Burner Mud Drum 1 1 Loss of Flame PT Economiser PT- 011 F.D. Fan Lube Oil Transmitter Steam Drum Level s AHH Effect XY-670 Oxygen Analyzer De-Energized Fan Cause is combined into one memory discrete value This is then used in all related effects AHH LT LT- 014 Effect XY-67 Fan Interposing The memory discrete is named # Active Steam Drum Level XY-670 Oxygen Analyzer FT XY-675 Lube Oil Aux. Pump 9 9 Interposing RE Low Lube Oil /4 Low Low Combustion Air Flow 7 XY-67 FD Fan Interposing Low Low Lube Oil ControlDraw Users Page: 6 of 1

7 Diagram 4 - Boiler Startup Sequence Diagram Version: 107 Class: Phase Diagram 4 of 6 PageID: 1 This diagram is under development. The Flowchart is not complete, but at present shows how the model can represent the flowchart using Special '_SetSymbols' objects. These link the text in the steps to the obects in the model. This ensures that object references are correct, and that tagname changes propagate. The Flowchart has been converted to a Sequential Function Chart. Review Status: Under Development ReviewStatus special object - shows the development status of the diagram as set in page details. Startup Sequence.pdf (Source files reference object) The flowchart is an image from the Horizon Visio-Boiler Startup Sequence.pdf file. It will be deleted, leaving just this document reference when the sequence in the model is appproved. T 01 Start S01 Start F.D. Fan Operator Prompt S 0 Verify Purge T0 F.D. Fan Running Operator Confirm T 0 FT-0156.AL = False FT-0156.AH = False _SetSymbols special objects - show a list of settings for objects in the model S 0 Permissives T 04 XV-664. = True 'Pilot Gas Block Valves XV-666. = True XV-667. = True 'Fuel Gas Block Valves XV-669. = True BS-017. = True 'Flame not present BS-018. = True S 04 T 05 PT-660.AHH = Off PT-6045.ALL = Off PT-010.AHH = Off 01 Active = False S 05 S 06 T 06 T 07 ControlDraw Users Page: 7 of 1

8 Description for Diagram 1-01 Low Low Steam Drum Level Diagram 1-01 Diagram Version: 1 Class: Safety Control Function Diagram 1 of 6 PageID: 17 [Diagram ] LT-0106.AHH [Diagram ] LT-014.AHH oo 01 Active Low Low Steam Drum Level [Diagram ] LSLL-6046.blnVal Used by Cross Reference Tagname 01 Active Diagram 5 8 ControlDraw Users Page: 8 of 1

9 Description for Diagram 0-09 High High Furnace Diagram 0-09 Diagram Version: 96 Class: Safety Control Function Diagram 0 of 6 PageID: [Diagram ] PT-015.AHH 09 Active High High Fuel Gas Used by Cross Reference Tagname 09 Active Diagram 5 8 ControlDraw Users Page: 9 of 1

10 Description for Diagram 6-1 Fault Tree Low Low Steam Drum Level Diagram 6-1 Fault Tree Diagram Version: 11 Class: Control Module Diagram 6 of 6 PageID: 15 Formula TheValue =sngin1 + sngin F9 F9 - Put into Run mode to evaluate the logic Low Steam Drum Water Level Formula TheValue =sngin1 + sngin + sngin + sngin4 + sngin5 + sngin6 Formula TheValue = sngin1 * sngin Fuel Gas Valves Level measurents XV-CC LT-CC SOV-CC TMR Fuel Gas Valves 1 XV-667 XY-667 Fuel Gas Valves XV-669 XY-669 LT-0106 LT-014 LSLL-6046 Event Low Steam Drum Water Level Fuel Gas Valves Fuel Gas Valves 1 Fuel Gas Valves Level measurents XV-667 XY-667 XY-669 XV-669 LT-0106 LT-014 LSLL-6046 XV-CC LT-CC SOV-CC TMR Probability 1.01E E-04.0E-0.00E-0.75E E E E E-0.10E-0.10E-0.90E E E E-05.70E-05 Copy of Safire 1 Fault Tree F9 to Run Calculations! This diagram is scripted to generate the probabilities from the tree. It does not use the recursive logic that systems such as Safire deploys (although this is a possible development - ControlDraw is full of recursive functions) Instead simple formulae are used for each 'gate'. And's produce the product of the inputs, Or's Add them. This is programmed into the object dynamics. Event Formula Low Steam Safire Drum Links! Water Level TheValue =sngin1 + sngin + sngin + sngin4 + sngin5 + sngin6 : Fuel Gas Valves TheValue = sngin1 * sngin : Developments could link this Model Fuel to Gas the Valves Safire model, 1 if Safire is TheValue to be retained. =sngin1 + sngin : Fuel Gas Valves TheValue =sngin1 + sngin : Level measurents TheValue = sngin1 * sngin * sngin : XV-667 XY-667 XY-669 XV-669 LT-0106 LT-014 LSLL-6046 XV-CC LT-CC SOV-CC TMR ControlDraw Users Page: 10 of 1

11 Diagram 0 - Boiler Equipment Damage Diagram Version: 10 Class: Document Reference Diagram 0 of 6 PageID: 4 Equipment Damage Tube Rupture [Diagram ] 0 1 High Steam Loss of Downstream Users Boiler Feed pumps Failure Low Steam Drum Level [Diagram ] 01 1 Boiler Feed Water Flow Ctrl Fail Low Low Steam Drum Level [Diagram ] 1 4 [Diagram ] 1 Low Low Lube Oil Low Lube Oil This diagram is shows how an Event Tree can be drawn and linked to the relevant diagrams. The links are jumps because the diagram is informative rather than being data generating. An alternative structure could be used where this type of diagram is actually a data generating parent however at present this model is not structured that way. ControlDraw Users Page: 11 of 1

12 Diagram 1 - Boiler Event Trees Diagram Version: 10 Class: Document Reference Diagram 1 of 6 PageID: 4 This diagram is shows how an Event Tree can be drawn and linked to the relevant diagrams. The links are jumps because the diagram is informative rather than being data generating. An alternative structure could be used where this type of diagram is actually a data generating parent however at present this model is not structured that way. SIS Blue number links to the relevant Cause diagram Interlock High Combustibles / Explosions Loss of Flame I [Diagram ] Loss of Flame Loss of Pilot 0 Flame 14 [Diagram ] 09 0 High Furnace Stack Damper Failure [Diagram ] [Diagram ] Low Fuel Gas Loss of Supply [Diagram ] High Fuel Gas [Diagram ] Air/Fuel Controller Failure 07 Low Combustion Air Flow 18 Air Flow Controller Failure Combustion Air Fan Trip [Diagram ] Low Pilot Gas Control Failure Loss of Supply ControlDraw Users Page: 1 of 1

13 Diagram - Copy of Safire 1 Fault Tree Diagram Version: 111 Class: None Diagram of 6 PageID: 19 Safire version ControlDraw Users Page: 1 of 1

14 Diagram - Hardware Concept Diagram Version: 109 Class: None Diagram of 6 PageID: 16 FIELD PANEL RACK ROOM BOILER Primary 110 VAC Primary 110 VAC Trident Enclosure Field Termination Strips Ignitor Homerun cable Flame Scanners DO to Field devices Trident Logic Solver, Comm Module & I/O Modules Redundant Acopian 4VDC P/S Fibre cable AI From Field devices From Field devices Operator Panels, Lights, Pushbuttons and Bypass Keyswitches Flame Scanners ControlDraw Users Page: 14 of 1

15 Diagram 4 - IO List connected to model Diagram Version: 108 Class: None Diagram 4 of 6 PageID: 18 This shows the original IO List from Horizon linked to the IO generated by the model. It is not yet fully resolved. Tag 6-XY UX-016 Description Pilot Gas Vent Valve Solenoid Local Panel Manual S/D Switch R-S-P Type DO Page Usertext 6-HS XY ZSC ZSC ZSO XY ZSC ZSC ZSC BS BS FT HS HS HS HS HS HS HS HS HS HS HS LSLL LT LT PSL PT PT PT PT UX UX UX UX UY XL XL XL XL-016-R 6-XL-016-S 6-XL XL-66 6-XL-66 6-XY XY XY XY-67 Control Room Boiler #1Manual S/D Switch Pilot Gas Header Shutdown Valve Solenoid Pilot Gas Header Shutdown Valve Pilot Gas Vent Valve Pilot Gas Vent Valve Open Pilot Gas Burner Shutdown Valve Solenoid Pilot Gas Burner Shutdown Valve Main Fuel Gas Header Shutdown Valve Main Fuel Gas Burner Shutdown Valve Pilot Flame Scanner Burner Switch Main Flame Scanner Burner Switch Combustion Air Flow Transmitter Steam Drum Bypass Switch Furnace Bypass Switch Combustion Air Flow Bypass Switch Flame Scanner Bypass Switch Pilot Gas Header Bypass Switch Fuel Gas Header Bypass Switch Start Burner Control Room Common Enable Fuel Gas Burner Bypass Switch Boiler Level Bypass Switch Start Purge Boiler Level Boiler Level Boiler Level Boiler Level Boiler Level Boiler Level Main Fuel Gas Control Valve at Low Fire Position Steam Drum Furnace Transmitter Pilot Gas Header F.D. Fan Lube Oil Transmitter Trident Common Trouble Alarm Boiler Fuel Gas Common S/D Boiler Air Group Common S/D Boiler Boiler Process Group Common S/D Ignitor Transformer Interposing Purging Lamp Pilot Flame Lamp Main Flame Lamp Boiler #1 Run Lamp Boiler #1 S/D Lamp Ignitor Lamp Purge Permissives Met Lamp Burner Permissives Met Lamp Main Fuel Gas Header Shutdown Valve Solenoid Main Fuel Gas Burner Shutdown Valve Solenoid Oxygen Analyzer Interposing F.D. Fan S/D Interposing DO DO AI AI AI AI AI AI AI AI AI DO DO DO DO DO Pilot Flame Scanner Burner Switch Main Flame Scanner Burner Switch Stm Drum Bypass Furnace Bypass Combustion Air Flow Bypass Flame Scanner Bypass Pilot Gas Header Bypass Switch Fuel Gas Hdr Press Bypass Start Burner Control Room Common Enable Fuel Gas Burner Press Bypass Boiler Lev Bypass Start Purge Low Low Steam Drum Level Steam Drum Level Steam Drum Level Steam Drum F.D. Fan Lube Oil Transmitter Trident Common Trouble Alarm Boiler 1601 Fuel Gas Common S/D Boiler 1601 Air Group Common S/D Boiler 1601 Boiler Process Group Common S/D Ignitor Transformer Interposing Purging Lamp Pilot Flame Lamp Main Flame Lamp Boiler #1 Run Lamp Boiler #1 S/D Lamp Ignitor Lamp Purge Permissives Met Lamp Burner Permissives Met Lamp Oxygen Analyzer FD Fan Interposing ControlDraw Users Page: 15 of 1

16 Diagram 5 - Original Cause and Effect Diagram Version: 119 Class: None Diagram 5 of 6 PageID: 14 Here the original Cause and Effect chart has been pasted in as a picture. ControlDraw does Cause and Effect charts via a collection of objects and links and a matrix, as shown on the process overview diagram ControlDraw Users Page: 16 of 1

17 Diagram 6 - SIL Results Diagram Version: 97 Class: None Diagram 6 of 6 PageID: 6 Original pasted in for reference esdstuff PFD HRF Safety Function Low Low Steam Drum Level High High Steam Drum Low Low Fuel Gas High High Fuel Gas Low Low Pilot Gas Loss of Combustion Air High High Furnace PFD 1.49-E E E E E E E-0 65 HRF Calc SIL 1 Req SIL Table from this model for class Safety Control Function (data not correct) RealTag U6.01 U6.0 U6.05 U6.06 U6.08 U6.09 U6.Effect XY-667 XY-669 U6.Effect FC-0159 U6.Effect XY-664 XY-666 U6.Effect XY-665 U6.Effect XY-670 U6.Effect XY-675 U6.Effect XY-67 U6.0 U6.04 U6.10 U6.11 U6.1 U6.1 PFD 1.49E E E E E E E E E E E E-0 HRF Calc SIL Rec SIL Usertext Low Low Steam Drum Level High High Steam Drum Low Low Fuel Burner Gas High High Fuel Burner Gas Low Low Pilot Gas Header High High Furnace Main Fuel Gas Shutdown Valves Main Fuel Gas Control Valve Pilot Gas Shutdown Valves Pilot GasVentValve Oxygen Analyzer De-Energized Lube Oil Aux. Pump Interposing Fan Interposing Loss of Flame Low Low Fuel Header Gas BSD Button Control Room BSD Button Low Lube Oil Low Low Lube Oil ControlDraw Users Page: 17 of 1

18 Data Report: Safety Control Functions ObjectTag page PageID Page Tag RealTag External Tag Logic PFD HRF Calc SIL Rec SIL 7 01 U U U U U U Effect XY- XY- 7 Effect XY-667 XY-669 Effect FC- 7 Effect FC-0159 Effect XY- XY- 7 Effect XY-664 XY-666 Effect XY- 7 Effect XY-665 Effect XY- 7 Effect XY-670 Effect XY- 7 Effect XY-675 Effect XY- 7 Effect XY-67 U6.Effect XY-667 XY-669 U6.Effect FC-0159 U6.Effect XY-664 XY-666 U6.Effect XY-665 U6.Effect XY-670 U6.Effect XY-675 U6.Effect XY U U U U U U U ControlDraw Users Page: 18 of 1

19 Data Report: Alarm Set points RealTag Caption Point SP ScaleMin ScaleMax EngUnits Message U6.FT-0156 AH U6.FT-0156 AHH U6.FT-0156 AL U6.FT-0156 ALL U6.LT-0106 AH U6.LT-0106 AHH U6.LT-0106 AL U6.LT-0106 ALL U6.LT-014 AH U6.LT-014 AHH U6.LT-014 AL U6.LT-014 ALL U6.PT-010 AH U6.PT-010 AHH U6.PT-010 AL U6.PT-010 ALL U6.PT-015 AH U6.PT-015 AHH U6.PT-015 AL U6.PT-015 ALL U6.PT-019 AH U6.PT-019 AHH U6.PT-019 AL U6.PT-019 ALL U6.PT-011 AH U6.PT-011 AHH U6.PT-011 AL U6.PT-011 ALL U6.PT-6045 AH U6.PT-6045 AHH U6.PT-6045 AL U6.PT-6045 ALL U6.PT-660 AH U6.PT-660 AHH U6.PT-660 AL U6.PT-660 ALL ControlDraw Users Page: 19 of 1

20 Data Report: Control System IOList ObjectTag page RealTag IO Type Node Card Channel cs 9 U6.UX-605.DO 9 U6.UY-6056.DO 9 U6.UX-657.DO 9 U6.UX-658.DO 9 U6.UX-659.DO 9 U6.XL-016-R.DO 9 U6.XL-016-S.DO 8 U6.LSLL csai 7 U6.LT-0106.AI csai 7 U6.LT-014.AI csai 7 U6.PT-010.AI cs cs cs 8 U6.BS U6.BS U6.HS csai 7 U6.PT-6045.AI csai 7 U6.PT-660.AI csai 7 U6.FT-0156.AI csai 7 U6.PT-019.AI csai 7 U6.PT-015.AI csai 7 U6.PT-011.AI Sov cs Sov cs Sov cs Sov cs Sov cs csopen Sov cs cs cs cs cs cs 5 U6.XV-667.DOSov 5 U6.XV U6.XV-669.DOSov 5 U6.XV U6.FC-0159.DO 5 U6.XV-666.DOSov 5 U6.XV U6.XV-664.DOSov 5 U6.XV U6.XV-665.DOSov 5 U6.XV U6.XV-665.Open 5 U6.XY-670.DOSov 8 U6.PSL U6.Boiler Field startup 9 panel.xl-000.do U6.Boiler Field startup 9 panel.xl-017.do U6.Boiler Field startup 8 panel.hs U6.Boiler Field startup panel.xl-018.do U6.Boiler Field startup panel.hs-015. U6.Boiler Field startup panel.xl-6056.do U6.Boiler Field startup panel.hs U6.Boiler Field startup panel.xl-66.do U6.Boiler Field startup panel.xl-66.do U6.Boiler Field startup panel.hs-609. U6.Boiler Field startup panel.hs ControlDraw Users Page: 0 of 1

21 ObjectTag page RealTag IO Type Node Card Channel cs cs cs cs cs cs cs cs cs U6.Boiler Field startup panel.hs U6.Boiler Field startup panel.hs U6.Boiler Field startup panel.hs-660. U6.Boiler Field startup panel.hs-661. U6.Boiler Field startup panel.hs. U6.Boiler Field startup panel.hs U6.LSL U6.LSH U6.HS. 9 U6.XY-675.DO 9 U6.XY-67.DO ControlDraw Users Page: 1 of 1

CASE STUDY: SAFETY INSTRUMENTED BURNER MANAGEMENT SYSTEM (SI-BMS)

CASE STUDY: SAFETY INSTRUMENTED BURNER MANAGEMENT SYSTEM (SI-BMS) Mike Scott VP, Process Safety AE Solutions Greenville, SC 29507 Bud Adler Director, Business Development AE Solutions Lake Mary, FL 32746