CN104678955A - Risk-based optimization method for safety instrument system of heating furnace - Google Patents
Risk-based optimization method for safety instrument system of heating furnace Download PDFInfo
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- CN104678955A CN104678955A CN201510039046.9A CN201510039046A CN104678955A CN 104678955 A CN104678955 A CN 104678955A CN 201510039046 A CN201510039046 A CN 201510039046A CN 104678955 A CN104678955 A CN 104678955A
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B13/00—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion
- G05B13/02—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion electric
- G05B13/04—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion electric involving the use of models or simulators
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
Abstract
The invention discloses a risk-based optimization method for the safety instrument system of a heating furnace. The optimization method comprises the following steps: a, identifying safety instrument function loops of the heating furnace; b, applying protective layer analysis, and determining the safety integrity level required by each safety instrument function loop; c, establishing an analysis model by adopting a fault tree analysis method, and carrying out safety integrity level verification and erroneous shutdown rate calculation; d, according to the calculation result, comprehensively considering the reliability and availability of the safety instrument system, and optimizing the overall configuration for the safety instrument system of the heating furnace. Through danger and risk analysis, the safety integrity level of the safety instrument system is determined, the spurious trip rate of the heating furnace is reduced by changing the redundant structure of each safety instrument function loop under the precondition of meeting a target safety integrity level, and the frequency of trips caused by false operation of the safety instrument system of the heating furnace can be reduced as much as possible under the condition of guaranteeing the safe operation of the heating furnace.
Description
Technical field
The present invention relates to a kind of heating furnace safety instrumented systems optimization method based on risk.
Background technology
In process industrial field; particularly in petrochemical process; the effect of safety instrumented systems holds the balance; it is important protective seam; carry monitoring and security-related state parameter in process of production, take measures in time when finding the dangerous situation such as fault or exception, with the important safety instrument function such as Accident prevention generation, to be widely used in the process industrial such as oil, chemical industry field at present.Therefore the security performance of safety instrumented systems is directly connected to various dangerous matter sources, the security control of complete equipment and safeguard protection level, and then is directly connected to safety in production level.During a design safety instrumented systems, this safety instrumented systems should be made to have correct security function.In addition, must consider more than enough good being performed of safety instrument function energy, what safety integrity level was concerned about is exactly that security function can more than enough good being performed.Under normal circumstances, safety instrumented systems is static, passive, does not need human intervention.But when dangerous situation occurs, by quiet variation, can must correctly complete its security function.Safety instrumented systems design is unreasonable, not only can give personnel, potential threat that environment band is huge, also can cause device unplanned shutdown.Therefore, distribute safety instrumented systems rationally, one is the safe reliability can improving safety instrumented systems, and the risk of controlled process is reduced to an acceptable level; Two is the availabilities that can improve safety instrumented systems, reduces the unplanned shutdown because safety instrumented systems misoperation causes.
Publication number is the functional safety appraisal procedure that the application for a patent for invention of CN102034025A discloses a kind of safety instrumented systems, for carrying out authentic simulation, monitoring and functional safety assessment to safety instrumented systems, and the situation of change of research safety instrument system common cause failure, method comprises: safety instrumented systems carries out functional safety control to controlled system; Initial risks analysis is carried out to safety instrumented systems, determines safety integrity level; Whether authenticating security instrument system reaches determined safety integrity level; Change composition structure or the component devices of safety instrumented systems.
Heating furnace is as one of the most frequently used equipment of petrochemical unit, and its reliability directly has influence on the safe and stable operation of device.Designers carry out the safety of proterctive equipment for furnace design safety instrumented systems (as high in temperature height, flow is low), but unreasonable due to safety instrumented systems design, bring potential danger and unplanned shutdown situation to device.
How the safety instrumented systems of reasonable disposition heating furnace, considers safe reliability and the availability of heating furnace safety instrumented systems, under the prerequisite ensureing heating furnace safety, reduces stop frequency by mistake, becomes the problem that people are more and more concerned about.It is therefore, reasonable, feasible that to arrange safety instrumented systems significant for ensuring equipment safe and stable operation.
Summary of the invention
Arrange unreasonable for heating furnace safety instrumented systems in prior art; there is the technical matters of " under proteciton " and " overprotection "; the present invention proposes a kind of heating furnace safety instrumented systems optimization method based on risk; the method is applied in heating furnace safety instrumented systems, has high, that parking rate the is low by mistake advantage of heating furnace reliability.
To achieve these goals, the technical solution used in the present invention is as follows:
Based on the heating furnace safety instrumented systems optimization method of risk, comprise the following steps:
The identification of the safety instrument functional loop of a, heating furnace;
B, application layer of protection analysis, determine each safety integrity level needed for safety instrument functional loop;
C, employing Fault Tree Analysis, set up analytical model, carries out safety integrity level checking and parking rate calculating by mistake;
D, according to above-mentioned result of calculation, consider the reliabilty and availability of safety instrumented systems, optimize the configured in one piece of heating furnace safety instrumented systems.
Further, in above-mentioned steps a, according to the process chart of heating furnace, pipeline and meter diagram and interlocking detail file, the consequence that the reason adopting the various parameter error of dangerous acupoint method identification and analysis to occur and this deviation produce, find out existing safety protection facility and measure of advising, reduce risk class further; The safety instrument functional loop that combing is existing and newly-increased, and list safety instrument function list.
Further, in above-mentioned steps b, on the basis of qualitative hazard analysis, the validity of assessment protective seam further.
Further, in above-mentioned steps c, adopt Development of FTA Software, the mutual relationship between system specific fault is figured according to Boolean logic, set up the oriented logical diagram describing fault from result to reason, input the failure parameter of each elementary event, carry out safety integrity level verification computation.
Further, in above-mentioned steps d, by changing the redundancy structure of each safety instrument functional loop, reduce the mistake parking rate of heating furnace.
Tool of the present invention has the following advantages:
The present invention adopts a kind of semiquantitative hazard analysis, methods of risk assessment, be beneficial to and solve " security " and " availability " problem in heating furnace day-to-day operation process, by dangerous and venture analysis, determine the reliability index of safety instrumented systems, i.e. safety integrity level, under the prerequisite meeting targeted security integrity levels, by changing the redundancy structure of each safety instrument functional loop, reduce the mistake parking rate of heating furnace, can under the situation guaranteeing heating furnace safe operation, reduce the frequency that the misoperation of heating furnace safety instrumented systems causes stopping as much as possible, greatly improve the safe and stable operation of heating furnace.
Accompanying drawing explanation
Fig. 1 is the schematic flow sheet based on the heating furnace safety instrumented systems optimization method of risk in the present invention;
Fig. 2 is the schematic flow sheet of layer of protection analysis in the present invention;
Fig. 3 is according to the mistake parking rate analytical model schematic diagram that Fault Tree Analysis is set up in the present invention;
Fig. 4 is according to another mistake parking rate analytical model schematic diagram that Fault Tree Analysis is set up in the present invention.
Embodiment
Below in conjunction with accompanying drawing and embodiment, the present invention is described in further detail:
Embodiment 1
Shown in composition graphs 1, based on the heating furnace safety instrumented systems optimization method of risk, comprise the following steps:
The identification in safety instrument function (SIF) loop of a, heating furnace;
B, application layer of protection analysis (LOPA), determine each safety integrity level (SIL) needed for safety instrument function (SIF) loop;
C, employing fault tree analysis (FTA) method, set up analytical model, carries out safety integrity level (SIL) checking and parking rate (STR) calculating by mistake;
D, according to above-mentioned result of calculation, consider the reliabilty and availability of safety instrumented systems, optimize the configured in one piece of heating furnace safety instrumented systems.
In above-mentioned steps a, according to data such as the process chart (PFD) of heating furnace, pipeline and meter diagram (P & ID) and interlocking explanations, the consequence that the reason adopting the various parameter error of dangerous acupoint (HAZOP) method identification and analysis to occur and this deviation produce, find out existing safety protection facility and measure of advising, reduce risk class further; Safety instrument function (SIF) loop that combing is existing and newly-increased, and list safety instrument function (SIF) inventory.
In above-mentioned steps b; on the basis of qualitative hazard analysis; the validity of further assessment protective seam, its objective is and determine whether risk to be reduced to tolerable risk level, determines the safety integrity level (SIL) in safety instrument function (SIF) loop.The basic flow sheet of layer of protection analysis as shown in Figure 2.
In above-mentioned steps c, adopt Development of FTA Software, the mutual relationship between system specific fault is figured according to Boolean logic, set up the oriented logical diagram describing fault from result to reason, input the failure parameter of each elementary event, carry out safety integrity level (SIL) verification computation.
Further, in above-mentioned steps d, by changing the redundancy structure of each safety instrument functional loop, reduce the mistake parking rate of heating furnace.
Wherein, two key interlockings of heating furnace are: furnace charge flow is low, the low interlocking of furnace fuel atmospheric pressure.
The embodiment of the present invention 1, by carrying out danger and venture analysis to heating furnace, finds out the key element affecting heating furnace stable operation; Safety instrument function (SIF) loop that identification safety instrumented systems is correct, determines the safety integrity level (SIL) of the safety instrumented systems relevant to heating furnace, and carries out safety integrity level (SIL) verification computation.According to assessment result, optimize safety instrumented systems control program, increase, change or extract existing safety instrument function (SIF) loop.While risk is reduced to acceptable risk level by the embodiment of the present invention 1, effectively can reduce the mistake stop frequency of heating furnace.
Clearly, identification SIF (Safety Instrumented Function) exactly, be one of primary work of analyzing of SIL deciding grade and level.Defining safety instrument function in IEC61508 is " reduce by electrical/electronic/programmable electronic safety-related systems, other technologies safety-related systems or Outer risks the function that facility performs, this function makes for a certain particular risk event or to maintain controlled plant in a safe condition ".The safe condition of controlled plant is defined as the state having broken away from unacceptable risk.It is " have certain specific SIL, in order to reach the security function of functional safety, it both can be an instrument safety defencive function, also can be instrument safety controlling functions " that IEC61511 defines safety instrument function.In other words, safety instrument function is exactly the action that safety instrumented systems is taked in order to the safety of whole process when potential danger occurs.In order to make process enter safe condition, this action must be performed with certain probability, the Safety Integrity Levels of this function that Here it is.
The required SIL in SIF loop of safety instrumented systems SIS (Safety Instrumented Systems) is determined by the risk after the disabler of assessment safety instrument, and these risks comprise casualties, environmental disruption and economic loss.The present invention's application layer of protection analysis (LOPA), determines each SIL needed for SIF loop.The data that LOPA derives from dangerous and operability analysis are set about, and cause reason and prevention or alleviate the danger that dangerous protective seam calculates each identification by documenting.So the total amount that risk reduces just can be determined and the need of reducing the risk analyzed further.And if it is provide this reduction with the form of a SIF that the risk as added reduces, LOPA method allows the SIL determining suitable SIF.
Fault tree analysis (FTA) figures mutual relationship between system specific fault according to Boolean logic, and it carries out rational analysis to the fundamental cause that fault occurs, and then sets up the oriented logical diagram describing fault from result to reason.
Its ultimate principle is as the target of fault analysis and starting point using the malfunction least wishing in institute's Study system to occur or event of failure, then, find the whole factors directly causing this fault to occur in systems in which, it can be used as the ground floor reason event of not wishing the fault occurred, then again with each reason event in this one deck for starting point, find whole factors of the next stage causing each reason event to occur respectively, by that analogy, until tracing that those are original, till failure mechanism or probability distribution be all known factor.Describe with it that the cause-effect relationship of fault is intuitive, clear, clear thinking, logicality strong, both can qualitative analysis, again can quantitative test.
Embodiment 2
The present embodiment 2 is for the feed for disproportionation heating furnace in Aromatic Hydrocarbon United Plant, and this heating furnace sends into reactor R-501 after feed for disproportionation is heated to temperature of reaction.In order to ensure the safe operation of heating furnace, production unit is provided with maltilevel security measure for it, and safety instrumented systems is one of them important protection facility.
The low interlocking of, feed rate low for furnace fuel atmospheric pressure, carries out the checking of its embodiment based on the heating furnace safety instrumented systems optimization method of risk and explanation.Concrete, comprise the following steps:
1, the identification in safety instrument function (SIF) loop
The consequence that the reason adopting the various parameter error of dangerous acupoint (HAZOP) method identification and analysis to occur and this deviation produce, finds out existing safety protection facility and measure of advising, reduces risk class further.
In order to protect heating furnace, devise that stove feed for disproportionation flow is low, fuel gas manifold pressure is low.
The safety instrument function that this heating furnace realizes comprises:
1), fuel gas manifold pressure too low time, the charging of fuel shutoff gas, prevents from occurring because stove stops working that heating furnace fuel gas gathers and the chance naked light blast that causes;
2), furnace charge flow too low time, the charging of fuel shutoff gas, damages boiler tube to avoid occurring boiler tube dry combustion method.
2, targeted security integrity levels (SIL) is determined
The security function in safety instrument function (SIF) loop that heating furnace F-501 picks out, trigger event or reason and risk status etc. are analysed item by item and record is discussed.
Consider casualties risk, environmental impact risk and the required safety integrity level of economic loss risk (SIL), then select SIL grade that wherein demand is higher as the SIL grade of particular safety instrument function (SIF) loop requirements.
Wherein, SIL deciding grade and level result is as shown in table 1.
Table 1 F-501 heating furnace safety instrumented systems SIL defines the level result
3, safety integrity level (SIL) checking and parking rate (STR) calculating by mistake
Adopt fault tree analysis (FTA) method, founding mathematical models, brings fail data into, and carry out safety integrity level (S IL) verification computation, accordance evaluation result is as shown in table 2.
Table 2 F-501 heating furnace SIL the result
Adopt fault tree analysis (FTA) method, set up parking rate (STR) computation model by mistake, bring Safe Failure data into, carry out mistake parking rate (STR) and calculate.Mistakenly stop car computation model as shown in Figure 3.
The mistake parking rate calculating F-501 is STR1=5.55E-2, and namely the mistake parking rate of F-501 is 0.055 times/year.
4, safety instrumented systems optimization
For certain differential pressure transmitter, according to the result of calculation of different redundancy structure, the impact of redundancy structure on PFD and STR is described, control to provide theoretical foundation for optimizing safety instrumented systems, result of calculation is as shown in table 3.
The different redundancy structure contrast of certain differential pressure transmitter of table 3
| Redundancy structure | PFD | STR |
| 1oo1 | 1.30E-2 | 1.39E-2 |
| 1oo2 | 1.68E-4 | 2.77E-2 |
| 2oo2 | 2.58E-2 | 1.95E-4 |
| 2oo3 | 5.01E-4 | 5.78E-4 |
Note: PFD is for requiring failure probability (Probability of Failure on Demand).
According to Functional Safety Standard IEC61508/61511, for SIF01 loop, in order to meet the requirement of SIL grade and structural constraint, and have lower mistake parking rate, the low interlocking of furnace fuel atmospheric pressure adopts the sensor of 2oo3 structure.Clearing obtain PFD=1.70E-3, meet SIL2 class requirement, as shown in Figure 4.
Adjustment misses the redundancy structure of parking rate (STR) computation model, and calculate: STR2=0.052, namely the mistake parking rate of F-501 is 0.052 times/year.
This shows that the interlock circuit configured according to this scheme optimization possesses high reliability and availability, run significant for ensuring equipment safety and steady.
Certainly; more than illustrate and be only preferred embodiment of the present invention; the present invention is not limited to enumerate above-described embodiment; should be noted that; any those of ordinary skill in the art are under the instruction of this instructions; made all equivalently to substitute, obvious form of distortion, within the essential scope all dropping on this instructions, protection of the present invention ought to be subject to.
Claims (5)
1., based on the heating furnace safety instrumented systems optimization method of risk, it is characterized in that, comprise the following steps:
The identification of the safety instrument functional loop of a, heating furnace;
B, application layer of protection analysis, determine each safety integrity level needed for safety instrument functional loop;
C, employing Fault Tree Analysis, set up analytical model, carries out safety integrity level checking and parking rate calculating by mistake;
D, according to above-mentioned result of calculation, consider the reliabilty and availability of safety instrumented systems, optimize the configured in one piece of heating furnace safety instrumented systems.
2. the heating furnace safety instrumented systems optimization method based on risk according to claim 1, it is characterized in that, in described step a, according to the process chart of heating furnace, pipeline and meter diagram and interlocking detail file, the consequence that the reason adopting the various parameter error of dangerous acupoint method identification and analysis to occur and this deviation produce, find out existing safety protection facility and measure of advising, reduce risk class further; The safety instrument functional loop that combing is existing and newly-increased, and list safety instrument function list.
3. the heating furnace safety instrumented systems optimization method based on risk according to claim 1, is characterized in that, in described step b, on the basis of qualitative hazard analysis, and the validity of assessment protective seam further.
4. the heating furnace safety instrumented systems optimization method based on risk according to claim 1, it is characterized in that, in described step c, the mutual relationship between system specific fault is figured according to Boolean logic, set up the oriented logical diagram describing fault from result to reason, input the failure parameter of each elementary event, carry out safety integrity level verification computation.
5. the heating furnace safety instrumented systems optimization method based on risk according to claim 1, is characterized in that, in described steps d, by changing the redundancy structure of each safety instrument functional loop, reduces the mistake parking rate of heating furnace.
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