11th International TV Rheinland Symposium

Functional Safety in Industrial Applications

May 13 14, 2014, Cologne - Germany

Bernhard Hoffmann
RWE Power Aktiengesellschaft - Germany

SIL in Power Stations Status, Experiences and Further Developments

SIL in Kraftwerken Status, Erfahrungen und weitere Entwicklungen

SIL IN POWER STATIONS

Status, Experiences and further
Developments
Contact
Bernhard Hoffmann | RWE Power AG | Energiestr. 10, 41517 Grevenbroich
T: +49 2181-26-3562 | bernhard.hoffmann@rwe.com

SIL in power stations

AGENDA

Introduction
Status of EN 50156 for furnaces and EN 764-7
Consequences for Europe due to the ammendment of pressure
equipment directive
Status of Technical Rules VDMA 4315 for turbomachinery and
generators
Status of VGB-S-008

VGB PowerTech e.V. | 14 February 2013 | SLIDE 3

SIL in power stations

STANDARDS FOR INSTALLATIONS IN

EUORPEAN POWER STATIONS
Steam Boiler Installations
Pressure Vessel Installations

Turbo-Generating Set
Conveying Systems

Pressure Equipment Directive

97/23/EC

Machinery Directive
2006/42/EC

EN
13480

EN
13445

EN
12952

VGB-S-008

EN
12953

EN 50156

EN ISO 12100

EN
62061

EN ISO
13849

PL

EN
61511
+
VDMA
4315

Ammonia Systems
Seveso-II-Directive
96/82/EC

EN 61511

Harmonised to:
97/23/EC
2006/95/EC
2006/42/EC
VGB PowerTech e.V. | 14 February 2013 | SLIDE 4

EN 61508

SIL
Management of functional Safety

VDI/VDE
2180

SIL in power stations

REVISION OF EN 50156 FOR

FURNACES

Part 1 is in the Final Vote

Part 2 is in the Final Vote
Part 3 is in preparation

VGB PowerTech e.V. | 14 February 2013 | SLIDE 5

SIL in power stations

REVISION OF EN 50156 FOR

FURNACES
Protective Device
2.10. annex I PED

Safety Accessories

Monitoring Devices

2.1.3 paragraph 1 PED

Point 2.10. b) annex I PED

Devices for direct pressure

limitation
Safety valves
Bursting disc safety devices
Controlled safety pressure relief
systems (CSPRS)
e.g.: EN ISO 4126-series

VGB PowerTech e.V. | 14 February 2013 | SLIDE 6

Limiting Devices

Pressure switches
Temperature switches
Fluid level switches
Safety related measurement
control and regulation (SRMCR)
e.g.: EN 12952-11
EN 12953-9
EN 50156-series

SIL in power stations

REVISION OF EN 50156 FOR

FURNACES AND EN 764-7
EN 13480
Pipes

EN 13445
unfired pressure
Vessels

EN 12952
Tube boiler

EN 12953
Shell boiler
6,8,9

EN 676
Automatic forced
draught burners for
gaseous fuels

EN 764-7
Safety systems for unfired
pressure equipmentt

7
EN 267
Automatic forced
draught burners
for liquid fuels

Not normative!
EN 61511
Functional Safety
Safety instrumented systems for
the process industry sector

EN 50156-1
Electrical equipment
for furnaces

EN 61508

VGB PowerTech e.V. | 14 February 2013 | SLIDE 7

Harmonised to:
RL 97/23/EC
RL 2006/95/EC
RL 2006/42/EC

SIL in power stations

REVISION OF EN 50156 FOR

FURNACES (NEW PART 2)
Safety related System
(EN 50156-1)
Sensor

Logic

Actuator

Subsystem and Devices (EN 50156-2)

EN 161
EN 267
EN 298

EN 676
EN 1643
EN 1854

VGB PowerTech e.V. | 14 February 2013 | SLIDE 8

EN 12067-2
EN 12952-11
EN 12953-9

EN 13611
prEN 16340
ISO 23552-1

EN 60947-2
EN 61800-5-2
EN 61508

SIL in power stations

AMMENDMENT OF PRESSURE
EQUIPMENT DIRECTIVE (PART 1)

The pressure equipment directive will be amended till middle of

the year
In the new pressure equipment the manufacturer will be new
defined:
manufacturer means any natural or legal person who
manufactures a pressure equipment or an assembly or has
such an equipment or an assembly designed or
manufactured, and markets that pressure equipment or
assembly under his name or trademark or uses it for his
own purposes; This is contradictory to recital (7). How
should be the difference between assembley vs. installation
identified according to guideline 3/2.

VGB PowerTech e.V. | 14 February 2013 | SLIDE 9

SIL in power stations

AMMENDMENT OF PRESSURE
EQUIPMENT DIRECTIVE (PART 2)
This means that for

limiting devices, which either activate the means for correction

or provide for shutdown or shutdown and lockout, such as
pressure switches or temperature switches or fluid level switches
and

"safety related measurement control and regulation

(SRMCR)" devices

a notified body accreditated in accordance to the pressure

equipment directive has to be involved in the quality assessment
even if it is installed for own purpose
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SIL in power stations

AMMENDMENT OF PRESSURE
EQUIPMENT DIRECTIVE (PART 3)

But even in this edition no specific requirements for limiting

devices of SRMCRs are added to the annex 1
As a consequence it was not possible to harmonise standards
based on IEC 61508 to the pressure equipment directive

VGB PowerTech e.V. | 14 February 2013 | SLIDE 11

Stand SIL

SAFETY LIFECYCLE COVERED BY VDMA 4315

concept and scope definition

VDMA 4315
Turbo-Set
Compressors

hazard and risk analysis

safety requirements allocation

planing
operation
and
maintenace
planing

design
validation
planing

Installation
and
comissioning
planing

back to
appropiate
phase within
saftey
lifecycle

installation and commissioning

safety validation
operation and maintenance
decommissioning

VGB PowerTech e.V. | 14 February 2013 | SLIDE 12

modifiction
and
retrofit

SIL in power stations

STATUS VDMA 4315

VDMA 4315 Part 1 Basics (published)

VDMA 4315 Part 2 Retrofit and Modification (under preparation)
VDMA 4315 Part 5 Risk Assessment Steam Turbines (published)
VDMA 4315 Part 6 Risk Assessment Gasturbines (published)
VDMA 4315 Part 7 Risk Assessment Compressors (published)
VDMA 4315 Part 6 Generators (Final Vote)

VGB PowerTech e.V. | 14 February 2013 | SLIDE 13

SIL in power stations

SAFETY LIFECYCLE COVERED BY VGB-S-008

concept and scope definition

VGB-S-008
SIL for Steam
Boiler and
Pressure Vessels

hazard and risk analysis

safety requirements allocation

planing
operation
and
maintenace
planing

design
validation
planing

Installation
and
comissioning
planing

back to
appropiate
phase within
saftey
lifecycle

installation and commissioning

safety validation
operation and maintenance
decommissioning

VGB PowerTech e.V. | 14 February 2013 | SLIDE 14

modifiction
and
retrofit

SIL in power stations

STATUS VGB-S-008

In addition to VDMA 4315 the technical specification VGB-S-008

covers the steam boiler system and the pressure systems in the
BOP of power stations
In the actual version the first three steps of the safety lifecycle
are covered
All other steps of lifecycle will be defined for power stations in
the running revision. (Planned Publishing in 2015)

VGB PowerTech e.V. | 14 February 2013 | SLIDE 15

SIL in power stations

Thank you for

your attention!

VGB PowerTech e.V. | 14 February 2013 | SLIDE 16