SIL
Safety Integrity Level (SIL)
SIL consulting is a technique to evaluate the current safety level of control systems quantitatively, so that it assists in selecting control systems and improves safety. SIL presents a rating and the probability to satisfactorily perform safety management functions that are required within a period of time. A higher SIL level means that the more management functions are performed.
Scope
- Petrochemical, oil refining process and storage facilities
- LPG station, Gas manufacturing / storage / use facilities, Refrigeration facilities, Toxic gas processing facility and Facilities where risks exist
Software
PHA-Pro V8
Strengths
- Reliability evaluation through analysis of instrumentation system
- Reassess risks after process improvement
Experience
- Yeochun NCC Co. #3 Plants
- LG Chem Co. , Daesan
- Honam Petrochemical Co., S-OIL Co. #1,#3 Plants
- Samsung Total, etc.
| SIL | PFD | 1/PFD |
|---|---|---|
| Safety Integrity Level | Probability of Failure on Demand per year (Demand mode of operation) |
Risk Reduction Factor |
| SIL4 | >=10⁵ to < 10⁴ | 100,000 to 10,000 |
| SIL3 | >=10⁴ to < 10³ | 10,000 to 1,000 |
| SIL2 | >=10³ to < 10² | 1,000 to 100 |
| SIL1 | >=10² to < 10¹ | 100 to 10 |
PFDavg Contribution
MTTFS Contribution
LOPA
LOPA
LOPA is a semi-quantitative risk assessment methodology that is quickly gaining a following in the chemical process industry. The fundamental purpose of conducting a LOPA for a process/project is to ensure that the risk reducation measures in place are consistent with the risk acceptance criteria established for the process/project.
A LOPA may additionally be used to generate the availability and reliability requirements for the SIS. These requirements are categorized in the form of SIL, based on the additional risk reduction required, or the target average probability of demand for the safety instrumented function.
| Safety Integrity Level | Probability of Failure on Demand per year (Demand mode of operation) |
Risk Reduction Factor |
|---|---|---|
| SIL4 | >=10⁻⁵ to < 10⁻⁴ | 100,000 to 10,000 |
| SIL3 | >=10⁻⁴to < 10⁻³ | 10,000 to 1,000 |
| SIL2 | >=10⁻³ to < 10⁻² | 1,000 to 100 |
| SIL1 | >=10⁻² to < 10⁻¹ | 100 to 10 |
Scope
- Petrochemical, oil refining process and storage facilities.
- LPG station, Gas manufacturing / storage / using facilities, Refrigeration facilities, Toxic gas processing facility and Facilities that risks exist
Software
PHA-Pro V8
Strengths
Reliability evaluation through out analysis of instrumentation system
Experience
- SK Energy MDU, MTBE plants / S-OIL Alkylation, SHU plants
- Boryoung LNG Terminal
QRA
QRA
Risk Assessment(RA) is a method of quantifying the risk by inducing main hazards that result in accidents on the process or facility sites and calculating the degree of the risk mathemetically. Through RA, you can know how risk levels are and compare each risk level on your site. This analysis give you comprehensive inspiration about safety and emergency response. In addition to this advantage, you can make a systematic evaluation of the risk from hazardous activities, and making a rational evaluation of their significance, in order to provide input to a decision-making process.
Scope
- Petro-Chemical, Petroleum Refinement process and Storage facilities
- Power plant, steel mill, water treatment facilities
- The flammable gas facilities like LPG station, gas manufacture ·storage·use·refrigeration·toxic gas disposal facilities
Key Technology
- Pre-Risk Assessment : Check List, HAZOP, FMEA, FMECA etc,.
- Accident frequency Analysis : Fault Tree Analysis, Event Tree Analysis, Human Error Analysis etc,.
- Consequence Analysis : Leak, Fire, Explosion, Vapour cloud dispersion simulation, Human effect calculation
- Risk Analysis : Indicating the degree of risk by Individual Risk, Societal Risk
- Providing Compresensive information about accidents or safety and Know-How
Software
DNV Phast-Risk v6.7
Strength
- Deducing a series of accident scenarios possible and prevention measure
- Identifying risk level of the facilities
- Deducting increase and decrease of risk level after process improvement
- Deducing the area of damage by accident and planing of emergency responce
Experience
- Posco Gwangyang steel mill / KOGAS Governor Station / Samchully / KDGAS / KOREA Hydro&Nuclear Power Co. / Samsung Total co,.
- KOGAS LNG Terminal / Posco Gwangyang LNG Terminal
- E1 / SKGAS / Korea Nation Oil Co. / SK Energy LPG Complex
HAZOP/HAZID
HAZOP/HAZID
Hazard and Operability Analysis (HAZOP) is a structured and systematic technique for system examination and risk management. In particular, HAZOP is often used as a technique for identifying potential hazards in a system and identifying operability problems likely to lead to nonconforming products. HAZOP is based on a theory that assumes risk events are caused by deviations from design or operating intentions. Identification of such deviations is facilitated by using sets ofguide words as a systematic list of deviation perspectives. This approach is a unique feature of the HAZOP methodology that helps stimulate the imagination of team members when exploring potential deviations.
Likeihood
| Frequency Classification | Level | Description |
|---|---|---|
| H | 1 | Hazard expected more than 1/year |
| M | 2 | Hazard expected several times in the plant life. |
| L | 3 | Hazard not expected at all in the plant life. |
Severity
| Frequency Classification | Level | Description |
|---|---|---|
| Catastrophic | A | Fatality serious injury hazard or hazard leading to loss of 6 months production or loss greater than $10M |
| Critical | B | lnjury hazard or hazard leading 10 loss of 1-6 months production or loss between $1-10M |
| Significant | C | Minor injury hazard or hazard leading to loss of 1-4 weeks production of loss between $0.1-1M |
| Minor | D | No injury hazard or hazard leading to loss of ˂1 weeks production or loss less than $100 000 |
Risk Ranking
| 1 | 2 | 3 | |
|---|---|---|---|
| A | Ⅰ | Ⅰ | Ⅲ |
| B | Ⅱ | Ⅱ | Ⅳ |
| C | Ⅲ | Ⅳ | Ⅳ |
| D | Ⅴ | Ⅴ | Ⅴ |
SYSTEM is the subject of a risk assessment and generally includes a process, product, activity, facility or logical system.
Scope
Microsoft Excel
Strengths
- Creative approch for identifying hazards, particularly those involving reactive chemicals
- Ehaustively examines the potential consequences of process upsets or failure to follow procedures
- Systematically identifies engineering and administrative safeguards and the consequences of safeguard failures
- Give all participants a thorough understanding of the system
Experience
- SK(INCHEON) LNG Terminal Unloading Sendout, Recirculation(TK 201~203, 219)
- Hyundai-steel ASU Plant
- Kogas LNG Terminal(TK)
- LG MMA #1 Plant
- GS Caltax HOU Plant
- Samsung BP VAM Plant
- OCIM S-2 Plant
RBM
RBM (Risk Based Management)
RBM is an integrated maintenance system managing risk level, inspection priority, inspection plan, inspection histories for each equipment. RBM is an integrated calculator provide detailed quantitative value of consequence of failure, probability of failure, financial/area risk based on API 580 and 581. With calculated risk data of each equipment, inspection plan can be made intensively and cost-effectively. RBM is a system that integrates risk assessment technology, equipment management module for drawing and document management, and preventive maintenance.
Scope
Upstream and downstream
Software
- KGS-RBM ver. 1.1
- Web & Stand-alone (Type)
- MS SQL Server (Database)
- ASP.net (Language)
KGS RBM Management Process
- Plant Database
- Risk Assessment
- Risk Matrix
-
- low
- A,B,1,2,3
- Medium
- C,D,4
- Medium high
- D,E,4,5
- High
- E,5
- Inspection Plan
- Inspection Result
- Inspection Updating
- System Management
- Drawing Management
- Document Management
- Preventive Maintenance
Strengths
- Risk Assessment
- - Provide quantitative numerical value of risk for each equipment.
- - Helps you to find out the equipment which are high on the list of priorities.
- - Reduce inspection costs and improve reliability without compromising plant safety.
- - Suggest inspection plans for equipment that identify the actions that should be implemented to provide reliable and safe operation.
- Drawing Management
- - User can easily check thickness data in the system indicated on the Assembly Drawing or Isometric Drawing.
- - KGS-RBM enables you to upload and download drawings such as Assembly Drawing, Isometric Drawing, P&ID, PFD for each equipment.
- Document Management
- - Inspection report, maintenance history and pictures can be managed with KGS-RBM. And based on the data in the system, user can create Inspection Work Order.
- - Our inspection report template enables user to upload and download inspection data in a way that is easier and more convenient.
- - Corrosion rate, remaining life and thickness transition curves are available on the system when user enters measured thickness data
- Preventive Maintenance
- - Make an optimal plan considering Regulation date, Remaining life, Time based inspection date.
- - You can check what equipment is need to be inspected and already inspected by year or by month at a glance with well displayed inspection report
Experiences
- GS Caltex NSU plants / SK Global chemical LDPE, HDPE, #1PP, 1-4BDO Plants
- YEOCHUN NCC #3 NCC Plants, KOREA Petrochemical Ind. Co. NCC Plants
- SK Incheon Petrochem #1CSU Plants / Samsung Fine Chemical #1ECH, MCT, NAO, HPM Plants
- LOTTE Chemical NCC, BTX Plants / LOTTE Advanced Materials PBL, EPS, #1,2 PC Plants
- Hanwha-Total NCC, C4, BTX, OCU, Utility, CFU, #1Aro Plants / POSCO SNG Plants
- LG Chemical NCC, EO, EG Plants / Ulsan Aromatics #1PX Plants
- DAELIM PB2 Plants / Hyundai Oilbank HCR Plants