HIMA-SELLA
Engineered Solutions for Safety Instrumented Systems S A F E T Y
C O N T R O L
&
A U T O M A T I O N
S Y S T E M S
your safety... our future
Engineered Solutions for Safety Instrumented Systems
“…a flexible approach to successful project delivery…” Hima-Sella has developed a strong reputation of proven expertise in the supply of safety critical and control systems to the process industries. Through its partnerships with key product suppliers and its in-house engineering capabilities, the company offers complete turnkey project capability which includes design, manufacture, engineering, test, installation management and commissioning. Hima-Sella’s reputation as a proven service provider is also maintained through its team of dedicated technical support personnel.
Project Management & Delivery Successful project management and delivery have a significant influence on the reputation of Hima-Sella in the UK markets. All projects are assigned a dedicated project delivery team who will ensure project milestones are achieved, client satisfaction is exceeded and that a philosophy of flexibility to delivery is maintained. Strong communication is key to the success of projects and the Hima-Sella project teams are encouraged to develop strong relationships with the client team. This is strengthened by the company's UK based project delivery teams.
Quality & CASS Certification In 2001, Hima-Sella was awarded CASS certificate 0001 from
On successful completion of all factory activities, the project
SIRA, for its compliance with IEC 61508 Functional Safety
teams have the necessary expertise to provide site installation
Management. The company's Quality Management System has
management and commissioning of the equipment.
been approved to BS EN ISO 9001 since 1989.
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your safety... our future
Consultancy & Design
Systems Support
Success in the delivery of sound engineered solutions has been
Hima-Sella has an established, dedicated team of technical
achieved utilising the experience of specialist teams. This
support engineers who ensure that clients receive maximum
experience is best utilised during the consultancy and design
benefit and reliability during the operational life of a system.
stages of a project. The engineering team's valuable knowledge
These highly trained and skilled engineers provide a range of
and experience can be called upon to improve the value of
services including 24/7 technical support and site attendance,
feasibility studies, risk assessment and whole life costing activities.
operational and maintenance training, system modifications and
In respect of safety applications, dedicated TĂœV approved
upgrades. All of these services are designed to ensure that
functional safety engineers are on hand to advise and/or
individual clients are offered the most cost effective solutions to
produce detailed functional design for many applications.
maintain system availability, and reliability.
Systems Integration and Testing The successful implementation of a system relies not only on thorough design processes but also extensive engineering and systems integration principles. The Hima-Sella approach utilises simple engineering procedures that have been proven through the implementation of many projects. Hima-Sella’s philosophy of a flexible, modular and open architecture design ensures simple integration of all equipment to third party applications. Detailed independent and fully integrated testing procedures are performed in-house proving system functionality in a safe environment before final commissioning tests are undertaken at site.
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Programmable and Hardwired Solutions
Programmable Electronic Systems (PES) HIMax HIMax, the new TĂœV certified SIL 3 safety controller from HIMA, is a highly scalable system (up to 12,000 I/O). It can be reconfigured both in programming and hardware without the need to shutdown or switch off. This means that the system has an almost 100% availability in an age where plant uptime is critical to profitability. Using its XMR technology, up to 4 main CPU modules can be used along with redundant I/O giving total flexibility in design. Even the classic 2oo3 configuration can be achieved or increased to 3oo4 if required for example. 1oo2 voting can be easily configured. Even with 1 CPU and single I/O the system is still SIL 3 rated. Main racks can be located in redundant peer-to-peer applications via safeethernet links over various media. Open communications architecture with gigabit ethernet processing allows connection to virtually any process controller on the market.
HIQuad HIQuad, can process a wide range of analogue and digital I/O types and can be integrated with all leading DCS systems. Its technology provides a high level of fault tolerance and process availability. Systems meet SIL 3 requirements without time limit, even in a non-redundant configuration. The HIQuad rack-mounting modular hardware enables users to engineer compact, scalable systems that can be easily adapted to meet changing requirements. Individual systems with up to 2048 I/O can be produced and systems can also be SIL 3 peerto-peer linked for larger applications even with a single communications link.
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your safety... our future
HIMatrix The HIMatrix range of safety-related controllers and remote I/O modules are designed to meet the
Failsafe Solid State Systems
requirements of small systems, offering an economic, reliable and flexible replacement for relay technology. The compact, DIN rail mounting products can be used in many applications, creating cost-effective solutions where the use of safety controllers would not normally be considered. The integrated ethernet switch enables distributed automation systems to be configured with a single central controller and local remote I/O modules. Safe ethernet communication allows safe and non-safe data to be combined on a standard ethernet network without compromising safety; a separate safety bus is not required.
SILworX - Common Software Tool SILworX is HIMA's latest programming package which is used not only to create the software and configure the hardware for the new HIMax system,
Planar 4 Hima-Sella, through its long association with HIMA since 1984, has a proven track record of providing custom solutions
but can be used to
for Solid State safety logic solver (Planar 4) to meet loop
configure systems for the
requirements up to SIL 3 in accordance with IEC 61508.
HIMatrix family as well.
The Planar 4 logic solvers are capable of many and varied
The software is designed
safety applications including ESD; Fire & Gas Detection; HIPPS;
to be identical to ELOP II
Zone 2 Hazardous areas; extreme temperatures (-20°c to
in its behaviour, whilst
+70°c), from small to large. Other applications areas are:
having additional features, such as better access control, improved diagnostics /
● Safety interlocks
error logging and an improved force editor to assist
● Voting logic panels
commissioning.
● Safety trip systems The HIMA Planar 4 Fail Safe Solid State System is based on a
3rd Party Devices
modular electronic circuit, with inherent fail safe logic built into
In providing IEC 61508 SIL rated logic solvers, Hima-Sella can also assist end users by providing complete systems from field sensors to final devices. Thus, in addition to the supply of supporting documentation as required for SIL rated systems, Hima-Sella would include for the supply of SIL rated devices such as: ● Trip Amplifiers (Moore/Amelec) ● Relays (Pilz / HIMA)
each circuit. This is achieved by using a 8Khz square wave frequency, generated on each module. This technique has been employed since 1978 and the Planar 4 is certified by the TÜV in accordance with IEC 61508 to SIL3/4. Enhanced diagnostics and communications have been integrated on each module using a DCM sub assembly, employed to help with maintenance and error detection. The DCM also enables the
● Solenoid Valves (Seitz)
Planar 4 System to communicate to third party systems, via RS
● Transmitters, manifolds
485 Modbus or Profibus, Ethernet (OPC server with protocol
and valves
TCP/IP), giving full details of trips, logic, input, output status, set points and analogue values.
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Safety-Critical Applications
Integrated Control & Safety Systems (ICSS) Hima-Sella has gained a great deal of process industry experience over the past 35 years, specialising in both safety shutdown and control aspects. These elements are engineered as separate departments which is important when meeting the requirement of IEC 61508, which states; “the EUC control system shall be separate and independent from the E/E/PE safety-related systems, other technology safety-related systems and external risk reduction facilities” It is vital that the controllers and associated I/O are of independent and diverse technology and this also applies to the engineering element. HIMA technology allows for total flexibility in choice of control systems via its ability to integrate with any recognised DCS control system. HIMA has a dedicated team of
industries and offer personnel, asset and environmental
the necessary experience for
protection by means of instantaneous, fail safe, plant
integration. This removes the
immobilisation.
might be restricted to a single vendor system. Hima-Sella offers a completely Integrated Control and Safety System (ICSS) by engineering
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Emergency Shutdown Systems are used across a wide range of
engineers who provide all
situation where the end user
HIMA-SELLA
Emergency Shutdown Systems (ESD)
The ESD is arguably the most widely used safety related application. It works by minimising the consequences of an onsite emergency by establishing and identifying safety critical signals which are then controlled and actioned to put the entire facility into a safe “stop” situation.
the integration rather than
A series of pre-engineered functions will then bring the facility
allowing manufacture to
back into full operation once the cause of the shutdown has
dictate the technology. In this
been determined and dealt with.
way the end user gets the
By offering programmable and non-programmable solutions,
best solution. Hima-Sella
Hima-Sella provides a versatile range of plant protection up to
also offers control systems
IEC 61508 SIL3. Whether the application requirement is for a
based on Allen Bradley,
small number of I/O signals or a complex system consisting of
Siemens and HIMA PLC
thousands, Hima-Sella has the expertise to design and build a
systems.
tailored ESD to meet client specifications.
your safety... our future
Burner Management Systems (BMS) Hima-Sella offers a number of solutions to best meet end user requirements for Burner Management Systems. These can be based on the HIMatrix distributed PES, allowing for the integration of the safety and control elements within a common system, using separate segregated hardware. This is useful on multi burner systems by enabling segregation of hardware for each burner. This flexible solution helps in the maintenance of the BMS.
Advantages of the Hima-Sella BMS solution: ● Increased burner reliability ● Certified to the latest standards ● Maximum safety (SIL 3/AK 6) even in mono configurations ● Maximum fault tolerance and availability in a redundant configuration ● The same extensive range of I/O modules for both large and small applications ● High reliability and simple maintenance due to extensive intelligent diagnostic functions ● Full graphic IEC-61131-3-compliant programming in ELOP II, pre-configured burner function blocks
Fire & Gas Detection (F&G)
● TÜV certified software function blocks
Hima-Sella Fire & Gas detection systems encompass a turnkey solution that includes sensing elements; HIMA TÜV certified logic solvers and protection devices. Hima-Sella provides equipment from approved third party suppliers and recognised gas detector companies. Protection devices such as deluge systems can also be supplied, typically in
By utilising its redundant properties, the HIMA HIQuad solution
oil and gas related industries, however a system can be
gives additional availability. For more complex or larger BMS
designed for virtually any scenario where fire and gas safety
requirements, the HIQuad system offers the capacity to give the
and availability are key.
performance required. In addition, communications facilities allow for the control system to be fully integrated with the safety critical element of the BMS, whilst still maintaining segregation.
HIMA fire and gas systems are programmable in order to cater for complex alarming arrangements, certified up to SIL 3 in accordance with IEC 61508 and offer line monitoring as standard. Single or dual I/O versions are available for increased availability but even the single I/O system logic solvers are SIL 3 certified. Typically, Fire and Gas systems are designed with dual communications links for increased availability and are offered in the following protocols: Modbus RTU slave RS485, ethernet OPC and Profibus DP slave. Consequently a wide range of connection possibilities with plant control systems are available.
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High Integrity Pressure Protection Systems (HIPPS)
Control Room/DCS
HIMatrix
SIL Rated
The High Integrity Pressure Protection Systems designed by Hima-Sella provide increased safety for pipelines and other critical plant where normal operation at higher pressures would not be permitted with ordinary ESD systems. Hima-Sella provides a complete turnkey solution for HIPPS, which is IEC 61508 SIL rated and encompasses the following elements: ● Pressure transmitters ● High integrity manifolds ● HIMA logic solvers - programmable and hardwired ● Fully piggable BEL ball or gate valves and actuators complete with partial stroke testing if required.
Tank Overfill Protection Solutions (TOPS) Hima-Sella’s tank overfill protection solution (TOPS), introduced following the major incident at the Buncefield fuel depot in 2005, provides reliable and highly cost effective protection for both plant and personnel. Specifically designed to automatically shutdown the supply transfer pipeline to petrol storage tanks, TOPS prevents overspills and the potential formation of highly flammable vapour clouds. Utilising HImatrix or HIMax programmable logic controllers, the system can protect either a single tank or a large multiple tank networked installation. With suitable level transmitters and valves it can be used in applications up to and including SIL 3.
Typically, certified pressure transmitters are used in the classic 2oo3 configuration for improved Probability of Failure on Demand (PFD). HIMA SIL 3/4 certified logic solvers - either with single or dual I/O for increased availability - can be mounted in
HIMatrix concepts for TOPS applications offer the following advantage:
safe areas or in EExnR, EExE and EExP applications for Zone 2
● Distributed, safety-related automation solutions
operation in harsh conditions. Valves can be supplied either as single or dual units for increased
● Installation of the safety controllers directly in EX Zone 2 (EN 50021,94/9/EC)
safety and the whole system can be TÜV certified for each
● Safety-related communication via a variety of media
individual installation, as required to meet national and
● Network availability by means of ring management
international regulatory requirements.
● Application specific increase in availability due to local installation of controllers and also parallel remote I/O lines ● A common network for safety-related and non safetyrelated data, project planning, configuration, diagnostics, visualisation, logging and remote maintenance ● Open protocol interfaces for tank station data transfer management systems
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your safety... our future
IEC 61508 & Functional Safety Consulting Certified Procedures Operating safely calls for compliance with best engineering practices. This means following internationally recognised standards that require a life-cycle approach to identifying, managing and reducing risk across all phases of a safety-critical installation. Hima-Sella works to ensure that every aspect of the safety life-cycle is addressed in a way that guarantees safe operation and full compliance with standards. The IEC functional safety management standard requires that procedures be compliant. Hima-Sella’s continued SIRA re-certification to the IEC 61508 standard demonstrates the
References Listed below is a selection of projects undertaken. Further details can be made available on request: ● ACG Project, Central Azeri - Instrumented Protection System (IPS) ● BP Coryton Refinery - Emergency Shutdown (ESD) ● Gas Compressor Station, Slovenia - Emergency Shutdown (ESD) ● EnCana Buzzard, North Sea - Emergency Shutdown (ESD) ● Exxon Esso, Fawley FCCU Olefins Project, Protective Instrument System (PIS) ● Statoil Hammerfest - Snøhvit - Multiple Safety Systems: ESD, HIPPS, SIS ● Huntsman, Wilton Jetty 3 Upgrade - Emergency Shutdown (ESD) ● Ineos Chlor Genesis - Emergency Shutdown (ESD)
company's dedication to maintaining the highest functional
● Irish Distillers Middleton - Emergency Shutdown (ESD)
safety standards and commitment to current best practice
● BP Grangemouth, Jetty 4 - Failsafe Shutdown System (ESD)
requirements, underpinned by the principles of integrity,
● Statoil KEP 2010 Kårstø Expansion Plant - ESD, HIPPS & CAP
transparency and consistency.
● OPC PTA Plant, Shanghai - Emergency Shutdown (ESD) ● Ormen Lange Mokveld - High Integrity Pressure Protection (HIPPS) ● NET 1, KEP 2005 & KEP 2010 - ESD & HIPPS ● Pearl GTL - High Integrity Pressure Protection (HIPPS) ● Rosetta Project, Egypt - Emergency Shutdown (ESD) and Fire & Gas Detection (F&G) ● Tengiz Project, Kazakhstan - Programmable Electronic System (PES) ● Terra Nitrogen - Burner Management System (BMS) ● Woqod LPG Bottling Plant - Integrated Control & Safety
Functional Safety Consultancy As a result of the above, Hima-Sella now provides clients
System (ICSS) ● Zakum Gas Injection, Abu Dhabi - High Integrity Pressure Protection (HIPPS)
with functional safety consultancy for complete systems including the provision of Technical Assessments to provide confidence that the required Safety Integrity Level can be achieved. This includes proposals for the field equipment types and part numbers. This consultancy can be independent of the technology of the logic solver ie it can be relay, solid state or PES - depending on the project specification. In addition, the consultancy can also include the conversion of specification requirements into functional logic.
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Hima-Sella Located in Stockport, Cheshire Hima-Sella has easy access to the motorway network, mainline railways and Manchester International Airport. Hima-Sella has custom built offices and workshops providing: ● Consultancy
Feasibility • Risk Assessment • Reliability Studies Whole Life Costing
● Project
On time delivery of project • Regular customer contact
Management
Agreed milestones to monitor progress
● Design
Detailed Design • Functional Logic • Auto CAD
● Engineering
Functional Design Specification • Safety Requirements Safety Requirements Specification
● Manufacturing
Panel Build • System Build • System Integration
● Testing
In-house • Factory Acceptance Testing • Site Acceptance Testing
● Commissioning
System Inspection • Support during Startup
● Technical Support
24 hour call out support • Upgrades/Modifications Maintenance (IEC 615O8 life cycle)
● Training
Hardware/Software Design • Maintenance and Servicing Customised courses
HIMA-SELLA HIMA-SELLA LIMITED SAFETY CONTROL & AUTOMATION SYSTEMS
Carrington Field Street, Stockport, Cheshire SK1 3JN United Kingdom telephone: +44 (0)161 429 4500 • facsimile: +44 (0)161 476 3095 email: sales@hima-sella.co.uk • web: www.hima-sella.co.uk
HS ENG SOL SAFT INST SYST v1 10/2010