The Background.

The Hydrogen Reformer at our client’s site has an existing SCADA Control System which has been identified as requiring replacement. Our client selected Booth Welsh (BW) for the design, manufacture and commissioning of a replacement control system and Safety Instrumented System (SIS) for the Hydrogen Reformer plant. Similar Safety Instrumented System projects had been effectively provided by BW to the client in recent years which gave confidence in our ability to successfully deliver.

The SIS scope consisted of 14 safety instrument functions (SIF’s) with a combination of SIL 1 and SIL 2 targets. A Programmable Logic Solver was pre-selected by the client for the project in this case a Siemens solution. The SIFs were identified by Hazard Analysis and the appropriate Safety Integrity Level assigned using Layers of Protection Analysis (LOPA).The Booth Welsh team took on overall responsibility of delivering the conceptual safety system design by preparing and reviewing the design documentation, specifying instrumentation, SIS panel design and build and the site installation, testing and commissioning records.

The Client

Our client is a supplier of industrial gases for a vast range of industries and processes, including the healthcare, chemical and automotive sectors. The client’s site produces Hydrogen through steam reforming of natural gas.

The Solution.

The Booth Welsh project team were responsible for the design and installation of the replacement control system and the new Safety Instrumented System. Our team of Functional Safety (FS) Engineers worked collaboratively with the client to deliver the SIS as per IEC 61511, client specifications and within agreed schedule.

Main Engineering Design Activities:

  • SIS Safety Lifecycle Plan
To deal with the challenge in a systematic manner BW prepared a SIS Safety Lifecycle Plan to ensure compliance with IEC 61511-1 the plan addressed the approach to the various activities including management of functional safety, lifecycle planning, auditing, assessment and verification.
  • SIS Safety Design Specification
The SIS Safety Design Specification documented a record of the ways in which the design of the PLC Base Safety Instrumented System complies with the Client Safety Requirements Specification (SRS).
  • SIL Verification Reports
The SIL Verifications for each safety function provided evidence that the SIL/RRF targets were met, taking into consideration factors outlined in Client SRS.
  • SIS Software Design Specification

A detailed document which outlined the processes controlled by the PCS7 System. The purpose of this document was to clearly define the structure of the BPCS and ESD software for PCS7.  The Software Design Specification was used as the basis for writing the software.Other Engineering Design Activities:

  • Detailed Design Drawings
  • Specification of SIL Capable Sensors, PLC, and Final Elements
  • O&M Manual
  • Inspection / Proof Test Procedures
  • Functional Safety Assessment (FSA) Stage 2. by Independent Third Party
  • Installation Inspection and Test Plan
Installation and Commissioning:
  • Installation and Commissioning carried out by CompEx Certified E&I Technicians
  • Test/Inspection records provided for Cable, Earthing, Loop Testing and Haz Area
Safety Validation:
  • Site Acceptance Testing
  • Functional Safety Assessment (FSA) Stage 3 by Independent Third Party

The Benefits.

Our ability to provide the full range of services in Design, Installation, Commissioning and Validation all under BW Scope, drives efficiencies in the delivery process introducing significant cost & time savings for the client.

Provide experienced competent Functional Safety Certified Engineers with recognized qualifications (CFSE, TUV Rhineland FS Eng.) with technical knowledge and skills across a variety of process industries.

Provide experienced and competent site-based supervision and technician team to carry out installation and commissioning.

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Assist the client to meet their environmental, safety, regulatory, and legislative obligations.

Training provided to operators.

Avoid Common Cause design errors throughout the project lifecycle.