SafetySIL Introductory Presentation

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Revolutionizing the way the Process, Production
Pipeline Industries Deal with Safety Critical
Systems
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SafetySIL
WELCOME To the Worlds First Only On-Line,
Fault-tolerant, Full-Stroke Testing Emergency
Shutdown Block Valve System
Revolutionizing the way the Oil Field Industries
Deal with Safety Critical Systems
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SafetySIL
INTRODUCING THE SafetySIL BLOCK VALVE SYSTEM
U. S. Patent No. 6,058,956
Revolutionizing the way the Oilfield Industries
Deal with Safety Critical Systems
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SafetySIL
Revolutionizing the way the Oilfield Industries
Deal with Safety Critical Systems
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SafetySIL
Revolutionizing the way the Oilfield Industries
Deal with Safety Critical Systems
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SafetySIL
Revolutionizing the way the Oilfield Industries
Deal with Safety Critical Systems
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SafetySIL
Revolutionizing the way the Oilfield Industries
Deal with Safety Critical Systems
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SafetySIL
Revolutionizing the way the Oilfield Industries
Deal with Safety Critical Systems
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SafetySIL
Revolutionizing the way the Oilfield Industries
Deal with Safety Critical Systems
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SafetySIL
Revolutionizing the way the Oilfield Industries
Deal with Safety Critical Systems
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SafetySIL
Revolutionizing the way the Oilfield Industries
Deal with Safety Critical Systems
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SafetySIL
Revolutionizing the way the Oilfield Industries
Deal with Safety Critical Systems
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SafetySIL
Applying the SafetySIL Regulatory
Oversight Operators Risk Strategy Safety
Integrity Level (SIL)
Revolutionizing the way the Oil Field Industries
Deal with Safety Critical Systems
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SafetySIL
FEDERAL STATE REGULATORY OVERSIGHT

• REQUIRES OPERATORS OF HAZARDOUS PROCESSES TO
• IDENTIFY AND MITIGATE ALL POTENTIALLY DANGEROUS
  EVENTS
• DANGEROUS EVENTS IMPACT SAFETY, HEALTH, AND THE
  ENVIRONMENT
• THEY ARE REQUIRED THEN TO EITHER
• REDUCE THE CONSEQUENCES IF THESE EVENTS OCCUR
• REDUCE THE PROBABILITY OF THEIR OCCURANCE TO A
  LEVEL DEEMED ACCEPTABLE.

Revolutionizing the way the Process Industries
Deal with Safety Critical Systems
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SafetySIL
OPERATORS RISK STRATEGY

• PROCESS HAZARD ANALYSIS (PHA) CONSISTS OF
• STUDYING THE PROCESS
• REDUCING THE PROBALILITY OF A DANGEROUS EVENT
• REDUCING THE RISK TO THE REQUIRED ACCEPTABLE
  LEVEL
• SAFETY INSTRUMENTED SYSTEMS (SIS) ARE INSTALLED
  TO REDUCE RISK
• SIS ARE ASSIGNED A SAFETY INTEGRITY LEVEL (SIL)

Revolutionizing the way the Process Industries
Deal with Safety Critical Systems
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SafetySIL
SAFETY INTEGRITY LEVEL (SIL)

• BASED ON (3) CHARACTERISTICS OF THE PROCESS AND
  SIS
• SHUTDOWN DEMAND RATE
• PROBABILITY TO FAIL UPON DEMAND (PFD)
• TESTING FREQUENCY
• EACH OF THESE FACTORS CAN BE ADDRESSED TO
  INCREASE THE SIL OF A SIS

Revolutionizing the way the Process Industries
Deal with Safety Critical Systems
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SafetySIL
INCREASING SIL

• ACTIVITIES THAT CAN RESULT IN A HIGHER SIL FOR A
  SIS
• RE-ENGINEERING PROCESS TO LOWER THE SHUTDOWN
  DEMAND RATE
• INCREASE MEAN TIME BETWEEN FAILURE (MTBF) OF
  SIS EQUIPMENT
• TEST SIS MORE FREQUENTLY

Revolutionizing the way the Process Industries
Deal with Safety Critical Systems
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SafetySIL
SIL RELATIONSHIP DEFINED
TESTING FREQUENCY ? SIL ? PDF ? SIL
? DEMAND RATE ? SIL ?
Revolutionizing the way the Process Industries
Deal with Safety Critical Systems
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SafetySIL
FREQUENCY TESTING

• EFFECTS SIL IN THE FOLLOWING WAYS
• ANY SYSTEM CAN MEET REQUIRED PFD IF IT IS
  TESTED FREQUENTLY ENOUGH
• FREQUENT FUNCTION TESTING CAUSES PROCESS
  INTERUPTIONS
• PROCESS INTERUPTIONS REDUCE PRODUCTION
  REVENUE
• PARTIAL STROKE TESTING DECREASES INTERUPTIONS,
  BUT ALSO DIAGNOSTIC COVERAGE

Revolutionizing the way the Process Industries
Deal with Safety Critical Systems
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SafetySIL
SIL LEVELS DEFINED

• RANGES OF (4) LEVELS OF SAFETY INTEGRITY (IEC
  61508)
• SIL 1 0.1 0.01 Failures / YR (1 to 10 or
  RRF 10-100 YRS)
• SIL 2 0.01 0.001 Failures / YR (0.1 to 1 or
  RRF 100-1,000 YRS)
• SIL 3 0.001 0.0001 Failures / YR (0.01 to
  0.1 of RRF 1,000-10,000 YRS)
• SIL 4 0.0001 0.00001 Failures / YR (0.001 to
  0.01 or RRF 10,000-100,000 YRS)
• (Note Administrative Procedures/Operator
  Actions are classed as SIL-1)(Interesting
  Note Safety Integrity Level is the same as the
  number of zeros)

Revolutionizing the way the Process Industries
Deal with Safety Critical Systems
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SafetySIL

• CONTRIBUTIONS TO SIS FAILURES OF THEFINAL
  CONTROL ELEMENT (BLOCK VALVE)
• MAJORITY OF DANGEROUS FAILURES CAUSED BY THE
  BLOCK VALVE
• MAJORITY OF NUISANCE TRIPS CAUSED BY THE BLOCK
  VALVE
• PRIMARY CHALLENGE IS FREQUENCY TESTING THE
  BLOCK VALVE
• ACHIEVING NEAR 100 DIAGNOSTICS WOULD SHUT DOWN
  THE PROCESS
• TESTING SYSTEMS CAN CAUSE COSTLY
  SPURIOUS/NUISANCE TRIPS
• Note Dangerous Failures are classed under
  Probability to Fail on Demand (PDF),
• Nuisance (spurious) Trips are classed
  under Mean Time To Fail Safe (MTTFS)

Revolutionizing the way the Process Industries
Deal with Safety Critical Systems
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SafetySIL
Revolutionizing the way the Process Industries
Deal with Safety Critical Systems
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SafetySIL
SIS SYSTEM DESIGN

• WHEN DESIGNING A SIS
• USE EQUIPMENT WITH A LARGE MTBF (DOESNT FAIL
  OFTEN)
• DESIGN FOR INCREASED TESTING FREQUENCY TO
  ACHIEVE THE PFD
• MOST VULNERABLE PART OF THE SIS IS THE FINAL
  ELEMENT (THE BLOCK VALVE)
• LATEST SIS DESIGNS FOR BLOCK VALVES DO NOT SOLVE
  THE PROBLEM

Revolutionizing the way the Process Industries
Deal with Safety Critical Systems
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SafetySIL
SIS BLOCK VALVE DESIGN

• TWO (2) BLOCK VALVES IN SERIES
• INCREASE SAFETY WITHOUT THE NEED TO TEST MORE
  FREQUENTLY
• UNLIKELY THAT BOTH VALVES WILL HAVE FAILED AT
  THE SAME TIME
• DOUBLES THE CHANCE FOR A SPURIOUS/NUISANCE TRIP
• SIGNIFICANT POTENTIAL FOR LOST REVENUE,
  (COULD BE MORE COSTLY THAN OTHER ALTERNATIVES)

Revolutionizing the way the Process Industries
Deal with Safety Critical Systems
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SafetySIL
SIS BLOCK VALVE DESIGN

• PARALLEL BYPASS AROUND THE BLOCK VALVE
• ALLOWS FOR ON-LINE FULL STROKE TESTING
• INCREASES DIAGNOSTIC COVERAGE OF EACH TEST
• HUMAN ERROR ON BYPASS CREATES POTENTIAL FOR
  DANGEROUS FAILURE
• LIMITED TO SIL 1 RATING (BECAUSE OF THE HUMAN
  INTERACTION)

Revolutionizing the way the Process Industries
Deal with Safety Critical Systems
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SafetySIL
SIS BLOCK VALVE TESTING

• PARTIAL STROKE TESTING
• BLOCK VALVE IS EXERCISED PARTIALLY CLOSED
• TEST PERFORMED WITH MINIMAL PROCESS INTERUPTION
• DECREASED DIAGNOSTIC COVERAGE VS. A FULL STROKE
  TEST
• WIDELY ACCEPTED THAT PARTIAL STROKE WILL CATCH
  60 80 OF FAILURES, BUT WHAT ABOUT THE
  OTHER 20 40?

Revolutionizing the way the Process Industries
Deal with Safety Critical Systems
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SafetySIL
SIS BLOCK VALVE TESTING
Revolutionizing the way the Process Industries
Deal with Safety Critical Systems
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SafetySIL
This screen print from a large, international
partial stroke testing manufacturer shows their
opinion of Partial Stoke Technology!
Revolutionizing the way the Process Industries
Deal with Safety Critical Systems
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SafetySIL
SIS BLOCK VALVE TESTING

• INDUSTRY NEEDS A BLOCK VALVE SYSTEM CAPABLE OF
• ON-LINE TESTING
• FULL STROKE TEST
• FAULT TOLERANT (NO SPURIOUS/NUISANCE TRIPS,
  REPAIRABLE ON-LINE)
• SIL CAPABLE
• NO PROCESS INTERUPTION, REGARDLESS OF THE
  TESTING FREQUENCY!!!

Revolutionizing the way the Process Industries
Deal with Safety Critical Systems
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SafetySIL
Revolutionizing the way the Process Industries
Deal with Safety Critical Systems
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SafetySIL
Revolutionizing the way the Process Industries
Deal with Safety Critical Systems
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SafetySIL
THE SafetySIL WHYS
Revolutionizing the way the Process Industries
Deal with Safety Critical Systems
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SafetySIL
THE SafetySIL WHYS

• WHY DOES THE SafetySIL INCREASE THE LEVEL OF
  PROTECTION
• ON-LINE, FULL STROKE TESTING
• TESTING AS FREQUENTLY AS REQUIRED TO ACHIEVE
  ANY SIL, EVEN SIL 4
• NEARLY 100 DIAGNOSTICS, INCLUDING OPERATION OF
  PLC I/O MODULES
• NO PROCESS INTERUPTION, REGARDLESS OF THE
  TESTING FREQUENCY!!!

Revolutionizing the way the Process Industries
Deal with Safety Critical Systems
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SafetySIL
THE SafetySIL WHYS

• WHY DOES THE SafetySIL DECREASE NUISANCE TRIPS
• FAULT TOLERANT TESTING SYSTEM
• TESTING WILL DETERMIME IF THERE IS ANY FAILED
  PART THAT WILL PREVENT EXPECTED OPERATION
• FAILED PART CAN BE REPAIRED ON-LINE WITH NO
  PROCESS INTERUPTION
• SPURIOUS/NUISANCE TRIP WILL NOT INTERUP PROCESS

Revolutionizing the way the Process Industries
Deal with Safety Critical Systems
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SafetySIL
THE SafetySIL WHYS

• WHY DOES THE SafetySIL SAVE YOUR OPERATIONS
  MONEY
• ELIMINATING SPURIOUS/NUISANCE TRIPS
• A TYPICAL SPURIOUS TRIP RATE (STR) CAN BE 3 4
  PER YEAR
• PREVENTION OF JUST (1) SPURIOUS TRIP CAN PAY
  FOR THE SYSTEM
• EACH ADDITIONAL SPURIOUS/NUISANCE TRIP
  PREVENTED IS PURE PROFIT!

Revolutionizing the way the Process Industries
Deal with Safety Critical Systems
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SafetySIL
THE SafetySIL WHYS

• WHY DOES THE SafetySIL DECREASE MAINTENANCE
  COSTS
• BLOCK VALVES CAN BE TESTED WHILE IN OPERATION
• NO NEED TO REMOVE A VALVE UNTIL IT FAILS (RUN
  TO FAIL)
• ON-LINE TESTING INSURES THE VALVES ARE
  FUNCTIONING AS EXPECTED
• REDUCTION IN MAINTENANCE COSTS ARE PURE PROFIT!

Revolutionizing the way the Process Industries
Deal with Safety Critical Systems
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SafetySIL
THE SafetySIL WHYS

• WHY DOES THE SafetySIL DECREASE T-I-Cs
• COSTS UPWARDS OF 30K TO 35K TO MOVE ONE
  SAFETY FUNCTION FROM SIL-1 TO SIL-2, OR FROM
  SIL-2 TO SIL 3. (MOVING FROM SIL-1 TO SIL 3 CAN
  COST UP TO 70K. ONE SafetySIL FUNCTION CAN
  PROVIDE SIL-4
• ELIMINATES NEED FOR MULTIPLE SIL-1 LAYERS OF
  PROTECTION
• CAN USE LESS EXPENSIVE VALVES AND OTHER
  EQUIPMENT (LOWER MTBFS)

Revolutionizing the way the Process Industries
Deal with Safety Critical Systems
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THE ONLY ON-LINE FULL STROKE TESTING FAULT
TOLERANT SIL CAPABLE BLOCK VALVE SYSTEM
THE REVOLUTION IN FAULT TOLERANT TECHNOLOGY!
Revolutionizing the way the Process Industries
Deal with Safety Critical Systems
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SafetySIL, LLCs PARTNERIN PRODUCTION, FACTORY
ACCEPTANCE TESTING ANDFIELD SUPPORT FOR

• INSTALLATION,
• CONFIGURATION
• MAINTENANCE
• TRAINING

Revolutionizing the way the Process, Oilfield
Pipeline Industries Deal with Safety Critical
Systems