VDMA Turbomachinery and generators Application of the principles of functional safety Part 2: Existing equipment

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1 VDMA-Einheitsblatt September 2015 VDMA ICS ; Turbomachinery and generators Application of the principles of functional safety Part 2: Existing equipment Turbomaschinen und Generatoren Anwendung der Prinzipien der Funktionalen Sicherheit Teil 2: Bestandsanlagen Continued page 2 to 35 Verband Deutscher Maschinen- und Anlagenbau e.v. (VDMA) Verband Deutscher Maschinen- und Anlagenbau e.v. All rights reserved to VDMA Verband Deutscher Maschinen- und Anlagenbau e.v., Frankfurt/Main Modification, amendment, editing, translation, copying and/or circulation only with permission in writing from VDMA. Exclusive sale: Beuth Verlag GmbH, Berlin Price group 15

2 Page 2 Contents Page Foreword... 3 Introduction Scope Normative references Terms and definitions Changes to existing equipment Evaluating changes Responsibility Significance of standards for functional safety Procedure when converting existing machinery General Scope of application of the principles of functional safety in existing machinery Equivalence Safety component as replacement part Conversion to new technology Replacing the entire protective circuit Installing a new protective function SIL requirement for a protective circuit risk assessment Protective circuit assessment scope Application of the principles of functional safety during repairs / maintenance Fundamental changes Examples cases (examples of conversion specifications) Generic example cases Practical examples of reconstruction measures Symbols and terms used Illustration of changes and assigned symbols Example cases... 24

3 Foreword Page 3 Turbomachinery has a service life of several decades. Existing equipment is therefore not necessarily built to the latest technology or to the state of the art, as is the case with new systems. Many existing installations were brought into circulation before the European Machinery Directive came into force and therefore do not satisfy the formal requirements of verification documentation. High requirements are placed on the safety of turbomachinery. The selection and realisation of the protective functions represent a significant aspect of turbomachinery safety. While existing machinery has used mechanical, hydraulic, pneumatic and electromechanical components for protective functions that have been proven over decades, new systems employ electrical, electronic and electronically programmable components. When existing equipment is modernised and renovated, the control and protective functions are frequently upgraded to the latest technology as well. Due to the nature of the new componentry, new standards for protective functions have been developed over the past few years under what is referred to as functional safety. Industry-specific standards for machinery (IEC and ISO 13849) and the process industry (IEC 61511) have been derived from the general standard (IEC 61508). Even though turbomachinery is safe and there is no specific reason to place in question the current high level of safety, this new standard of technology must be factored into new systems. The VDMA 4315 series of specifications provides recommendations of how to accommodate the latest requirements for turbomachinery and generators. This series of specifications has been produced by the manufacturers organised within the VDMA. Detailed explanations and background information on risk assessments can be found in VDMA Specification 4315 Turbomachinery and generators Application of the principles of functional safety Part 1 Methods for determination of the necessary risk reduction. The product-related risk assessments can be found in parts 5 to 8, which are published in conjunction with the VGB. Whilst VDMA 4315 principally deals with methods for determining the required risk reduction and determines the requirements for protective circuits (necessary risk reduction factors and SIL), without getting into specific implementation, Part 2 answers the question of how to proceed with renovating old equipment and provides clear tips on usage. This second part of the series of specifications firstly deals with the underlying questions that arise when reconstructing an existing installation in terms of the Machinery Directive and applying the standards for functional safety. Then, with these specifications, typical renovation projects are described in detail and illustrated with examples, and the requisite measures for protective functions (assessment re SIL) are listed. Here, renovation plans can be split into three different types: 1. Pure reconstruction or renovation of one or more protective functions for the purpose of modernisation or the replacing of componentry. 2. Retrofit (e.g. the delivery of a new partial machine for the purpose of increasing performance, control technology conversion). 3. Changing the application of turbomachinery (changing or enhancing process functions). If the modified protective function either all of it or parts of it is to be subjected to a SIL assessment as part of the reconstruction, then the relevant requirements (SIL) of the protective functions are to be taken from the risk assessments of the respective products (product-related parts of the VDMA 4315 series). The crucial factor for reconstruction assessment is answering the question of whether it constitutes a fundamental change of the overall machine. This results from the EU guideline for implementing the directives drawn up according to the new concept. In this it is noted under 2.1 that: Products which undergo considerable alterations (note: also fundamental change ), can be considered as new products. They must comply with the terms of the applicable directives. As the reconstruction of existing equipment is not always covered by the European Machinery Directive but primarily by European and local work usage regulations, this Part 2 has been provided with a uniform interpretation in joint meetings between manufacturers (VDMA) and operating organisations (VGB), so that the assessment provided here conveys the shared view of manufacturers and operating organisations. The renovation measures described merely serve as exemplary descriptions based on the broad experience of

4 Page 4 the experts involved. The steps and results shown here are to be taken as a practical starting point for a specific assessment. No claim is made with respect to the completeness of the document, nor to an exact interpretation of existing legal requirements. It must not be a substitute for study of the relevant directives, laws and ordinances for the conversion of equipment. Introduction This VDMA Specification is part of a series of specifications with the following parts: Part 1 Methods for determination of the necessary risk reduction Part 2 Existing plants Part 3 Not assigned Part 4 Not assigned Part 5 Risk assessment steam turbines Part 6 Risk assessment gas turbines Part 7 Risk assessment compressor train Part 8 Risk assessment hydrogen cooled generators The following companies were involved in the project work for applying the principles of functional safety in existing installations: Atlas Copco Energas MAN Diesel & Turbo and the trade associations the VDMA and VGB Power. This VDMA Specification has been prepared by the following experts: Bernhard Hoffmann Patrick Knopp Peter Richter Hartmut Strangfeld Jörn Wesche Dr Wilfried Blotenberg Dr Claus Eifert Thomas Haag Marcel Kern Frank Maeckle Dr Thomas Müller Bernhard Wüst Zeynep Yiğit-Rohde Matthias Zelinger VGB PowerTech MAN Diesel & Turbo Atlas Copco Energas VDMA Power Systems The VDMA Specification is published in co-operation with VGB PowerTech, Essen.

5 1 Scope Page 5 Part 2 of the VDMA 4315 series deals with the conversion of turbomachinery (compressors, steam turbines, gas turbines, power plant generators) that is already in circulation for power plant facilities and industrial applications at all power ranges. This part deals with the application of managing the principles of functional safety for reconstruction, replacement and enhancement of existing protective functions. Specific conversion plans are used to describe under which conditions interference in existing protective functions or in the overall safety system does not lead to a fundamental change to the machine.