基于功能安全的危化品源监控系统模型的搭建
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摘要
随着功能安全基础标准IEC 61508的发布及在我国的实施,“功能安全”成为安全生产领域的热门话题和技术热点。它在安全技术和管理理论两个方面对涉及人身及环境安全的各个方面提出要求,倡导了一种全新的保障安全的理念。
目前功能安全在我国处于起步状态,其在实际中的应用研究还不多。本文旨在国家863“面向安全监测与跟踪的网络化微系统”项目的依托下,通过对IEC61508及IEC 61511等功能安全标准的学习和研究,以车载危险化学品监测系统为载体,利用西门子S7-300F可编程序控制器(PLC)、按钮、指示灯搭建一个危化品运输监测装置的功能安全型模型,用STEP7进行硬件组态并编写了PLC的程序,用WinCC编写了上位机监控程序,并对系统进行了安全完整性等级(SIL)的验证。本文从功能安全的起源和发展入手,主要完成了以下工作:
(1)介绍了功能安全的国内外发展现状,功能安全相关标准的基础理论和要求;
(2)对移动危化品源进行了风险分析,并通过风险分析确定了监控系统模型拟实现的功能,如超限报警、紧急情况报警等,并对模型的安全完整性等级提出要求,要求模型实现的各报警功能应达到SIL 2;
(3)用西门子PLC及相关部件搭建了模型的硬件平台,对PLC进行了硬件组态,在STEP 7下用功能块完成了PLC编程,从而建立了一个功能安全模型系统;
(4)将模型系统上电运行,对其进行了功能测试;
(5)对模型系统进行了安全完整性验证和功能安全评估,结果显示模型系统达到了SIL 2等级,即满足了风险分析提出的要求。
With the basic standard of functional safety, IEC 61508, released and implemented in China, "Functional Safety" becomes a hot topic and a technology hot spot. The standard advocates a new concept of safety with the requirements both in technology and management, personal and environmental.
Functional safety is still a new theory now in China. In this paper, a model of mobile dangerous chemicals monitoring system is built with Siemens S7-300F PLC, buttons and lamps, in which functional safety related concepts and theory are used according IEC 61508, IEC 61511 standards.
First, the origin and development in China and abroad of functional safety is introduced, the basic theory and requirements in relative standards is illuminated.
Second, the functions of the model, such as overrun alarm and emergency alarm, are determined whose Safety Integrated Level (SIL) should be SIL 2 after risk analyze of dangerous chemicals monitoring system.
Third, the model is built, PLC is configured and programmed by STEP 7, PC program for monitoring the model is made by WinCC.
Fourth, functions of the model are tested.
And last, SIL of the model is validated to ensure that it is satisfied with the requirements requested in the risk analyze. During the verification, formulas for calculating PFH value of 1oo1D and 1oo2D structure are presented.
目前功能安全在我国处于起步状态,其在实际中的应用研究还不多。本文旨在国家863“面向安全监测与跟踪的网络化微系统”项目的依托下,通过对IEC61508及IEC 61511等功能安全标准的学习和研究,以车载危险化学品监测系统为载体,利用西门子S7-300F可编程序控制器(PLC)、按钮、指示灯搭建一个危化品运输监测装置的功能安全型模型,用STEP7进行硬件组态并编写了PLC的程序,用WinCC编写了上位机监控程序,并对系统进行了安全完整性等级(SIL)的验证。本文从功能安全的起源和发展入手,主要完成了以下工作:
(1)介绍了功能安全的国内外发展现状,功能安全相关标准的基础理论和要求;
(2)对移动危化品源进行了风险分析,并通过风险分析确定了监控系统模型拟实现的功能,如超限报警、紧急情况报警等,并对模型的安全完整性等级提出要求,要求模型实现的各报警功能应达到SIL 2;
(3)用西门子PLC及相关部件搭建了模型的硬件平台,对PLC进行了硬件组态,在STEP 7下用功能块完成了PLC编程,从而建立了一个功能安全模型系统;
(4)将模型系统上电运行,对其进行了功能测试;
(5)对模型系统进行了安全完整性验证和功能安全评估,结果显示模型系统达到了SIL 2等级,即满足了风险分析提出的要求。
With the basic standard of functional safety, IEC 61508, released and implemented in China, "Functional Safety" becomes a hot topic and a technology hot spot. The standard advocates a new concept of safety with the requirements both in technology and management, personal and environmental.
Functional safety is still a new theory now in China. In this paper, a model of mobile dangerous chemicals monitoring system is built with Siemens S7-300F PLC, buttons and lamps, in which functional safety related concepts and theory are used according IEC 61508, IEC 61511 standards.
First, the origin and development in China and abroad of functional safety is introduced, the basic theory and requirements in relative standards is illuminated.
Second, the functions of the model, such as overrun alarm and emergency alarm, are determined whose Safety Integrated Level (SIL) should be SIL 2 after risk analyze of dangerous chemicals monitoring system.
Third, the model is built, PLC is configured and programmed by STEP 7, PC program for monitoring the model is made by WinCC.
Fourth, functions of the model are tested.
And last, SIL of the model is validated to ensure that it is satisfied with the requirements requested in the risk analyze. During the verification, formulas for calculating PFH value of 1oo1D and 1oo2D structure are presented.
引文
[1]史学玲.功能安全标准的历史过程与发展趋势.仪器仪表标准化与计量.2006.2
[2]EMC And Functional Safety—Challenges And Standards.B.W.Jaekel.IEEE.2007
[3]IEC 61508:Functional Safety:Safety-Related Systems.John Brazendale.
[4]史学玲.中国功能安全现状与趋势研究.第六届工业自动化与标准化研讨会.北京.2008
[5]王令朝.解读应用功能安全性国际标准及其对铁路的作用.铁道技术监督.VOL.35 NO.12
[6]Hartmut yon Krosigk.Application of IEC 61508-1998 and expected changes in 2~(nd)edition.2008
[7]IEC.IEC 61508-2001.Funtional safety of electrical/electronic/programmable electronic safety related systems.1-7.2001
[8]南保昌孝.日本机械安全的现状.第二届机械安全标准与装备制造业安全生产国际研讨会论文.北京.2007
[9]冯晓升,史学玲.功能安全——一种保障安全的新思路.中国仪器仪表.2005.10
[10]李跃峰.功能安全国际标准的研究[学位论文].浙江大学.2007
[11]史学玲,冯晓升.功能安全与我国安全相关的产业创新模式研究.世界仪表与自动化.2006.11
[12]雷芳.危险化学品安全评价体系指标的研究[学位论文].中国地质大学.2004
[13]国家安全生产监督管理总局.《危险化学品道路运输安全监控车载终端》编制说明(征求意见稿).2005
[14]国家安全生产监督管理总局.《危险化学品道路运输安全监控系统通用规范》编制说明(征求意见稿).2005
[15]Roberto Bubbico,Cinzia Ferrari,Barbara Mazzarotta.Risk Analysis of LPG Transport by Road and Rail.Loss Prevention in the Process industries.2000.13
[16]刘茂,任军平,张宇.危险品公路运输风险分析方法及应用.中国公共安全.2005.12
[17]张春华.坚持综合治理强化危险化学品运输安全管理.交通标准化.2002.35
[18]童铠.中国导航定位卫星系统的进展.中国航天.2002.8
[19]李鹏飞.江苏省危险化学品道路运输动态监控现状分析[学位论文].江苏大学.2007
[20]姚峰.省内公路运输可移动危险源监控与应急救援研究[学位论文].江苏大学.2007
[21]吴志华.危险化学品运输综合监测系统研究[学位论文].北京交通大学.2007
[22]孙代平.一种危险化学品罐箱/槽车的实时监测系统[学位论文].大连理工大学.2006
[23]中国国际海运集装箱(集团)股份有限公司.国家高技术研究发展计划(863计划)重点项目“面向安全监测与跟踪的网络化微系统”申请书.2006
[24]冯晓升.功能安全基本概念的建立.仪器仪表标准化与计量.2007.1
[25]阳宪惠.郭海涛.安全仪表系统的功能安全.清华大学出版社.2007
[26]Goble W.Getting failure rate data.Hydrocarbon Processing.2002.81
[27]Alder B.IEC 61508/IEC 61511 Failure Rate Data-Validity Insights-The need for Certified Data Sets.Moore Industries International
[28]Bud Adler.Measuring Reliability(MTBFvs.FMEDA).Epigram Newsletter.2002
[29]洪玉,何海滨.液氯罐车的安全使用与维护.专用汽车.2005.5
[30]王执帆.西门子自动化技术在锅炉控制系统中的应用[学位论文].昆明理工大学.2006
[31]王欢.基于PROFIBUS现场总线的PLC控制系统研究与设计[学位论文].北方工业大学.2007
[32]柴瑞娟,陈海霞.西门子PLC编程技术及工程应用.机械工业出版社.2007
[33]GJB299B-1998.电子设备可靠性技术手册.1998
[34]西门子(中国)有限公司自动化与驱动集团.深入浅出西门子S7-300 PLC.北京航空航天大学出版社.2004
[35]Harry Cheddie P.The safety analysis of redundant SIF with incomplete or partial testing.exida.com.
[36]Hiroo Kanamaru,Tsuyoshi Mogi,Naoki Aoyama.Functional safety application using safety PLC.SICE Annual Conference.Kagawa University.2007.
[37]Aart Pruysen.Functional safety from a component supplier's viewpoint.IEE.2004
[38]Hartmut yon Krosigk.Functional safety in industrial automation.IEE.2001
[39]William.M.Goble.SIL verification-Process and problems.exida.com.2000.12
[40]Heinz Gall.The TUV approach to functional safety assessment and certification.IEE.2004
[41]F.J.Molina,J.Barbancho.Using industrial standards on PLC programming learning.2007Mediterranean Conference on Control and Automation.Greece.2007
[2]EMC And Functional Safety—Challenges And Standards.B.W.Jaekel.IEEE.2007
[3]IEC 61508:Functional Safety:Safety-Related Systems.John Brazendale.
[4]史学玲.中国功能安全现状与趋势研究.第六届工业自动化与标准化研讨会.北京.2008
[5]王令朝.解读应用功能安全性国际标准及其对铁路的作用.铁道技术监督.VOL.35 NO.12
[6]Hartmut yon Krosigk.Application of IEC 61508-1998 and expected changes in 2~(nd)edition.2008
[7]IEC.IEC 61508-2001.Funtional safety of electrical/electronic/programmable electronic safety related systems.1-7.2001
[8]南保昌孝.日本机械安全的现状.第二届机械安全标准与装备制造业安全生产国际研讨会论文.北京.2007
[9]冯晓升,史学玲.功能安全——一种保障安全的新思路.中国仪器仪表.2005.10
[10]李跃峰.功能安全国际标准的研究[学位论文].浙江大学.2007
[11]史学玲,冯晓升.功能安全与我国安全相关的产业创新模式研究.世界仪表与自动化.2006.11
[12]雷芳.危险化学品安全评价体系指标的研究[学位论文].中国地质大学.2004
[13]国家安全生产监督管理总局.《危险化学品道路运输安全监控车载终端》编制说明(征求意见稿).2005
[14]国家安全生产监督管理总局.《危险化学品道路运输安全监控系统通用规范》编制说明(征求意见稿).2005
[15]Roberto Bubbico,Cinzia Ferrari,Barbara Mazzarotta.Risk Analysis of LPG Transport by Road and Rail.Loss Prevention in the Process industries.2000.13
[16]刘茂,任军平,张宇.危险品公路运输风险分析方法及应用.中国公共安全.2005.12
[17]张春华.坚持综合治理强化危险化学品运输安全管理.交通标准化.2002.35
[18]童铠.中国导航定位卫星系统的进展.中国航天.2002.8
[19]李鹏飞.江苏省危险化学品道路运输动态监控现状分析[学位论文].江苏大学.2007
[20]姚峰.省内公路运输可移动危险源监控与应急救援研究[学位论文].江苏大学.2007
[21]吴志华.危险化学品运输综合监测系统研究[学位论文].北京交通大学.2007
[22]孙代平.一种危险化学品罐箱/槽车的实时监测系统[学位论文].大连理工大学.2006
[23]中国国际海运集装箱(集团)股份有限公司.国家高技术研究发展计划(863计划)重点项目“面向安全监测与跟踪的网络化微系统”申请书.2006
[24]冯晓升.功能安全基本概念的建立.仪器仪表标准化与计量.2007.1
[25]阳宪惠.郭海涛.安全仪表系统的功能安全.清华大学出版社.2007
[26]Goble W.Getting failure rate data.Hydrocarbon Processing.2002.81
[27]Alder B.IEC 61508/IEC 61511 Failure Rate Data-Validity Insights-The need for Certified Data Sets.Moore Industries International
[28]Bud Adler.Measuring Reliability(MTBFvs.FMEDA).Epigram Newsletter.2002
[29]洪玉,何海滨.液氯罐车的安全使用与维护.专用汽车.2005.5
[30]王执帆.西门子自动化技术在锅炉控制系统中的应用[学位论文].昆明理工大学.2006
[31]王欢.基于PROFIBUS现场总线的PLC控制系统研究与设计[学位论文].北方工业大学.2007
[32]柴瑞娟,陈海霞.西门子PLC编程技术及工程应用.机械工业出版社.2007
[33]GJB299B-1998.电子设备可靠性技术手册.1998
[34]西门子(中国)有限公司自动化与驱动集团.深入浅出西门子S7-300 PLC.北京航空航天大学出版社.2004
[35]Harry Cheddie P.The safety analysis of redundant SIF with incomplete or partial testing.exida.com.
[36]Hiroo Kanamaru,Tsuyoshi Mogi,Naoki Aoyama.Functional safety application using safety PLC.SICE Annual Conference.Kagawa University.2007.
[37]Aart Pruysen.Functional safety from a component supplier's viewpoint.IEE.2004
[38]Hartmut yon Krosigk.Functional safety in industrial automation.IEE.2001
[39]William.M.Goble.SIL verification-Process and problems.exida.com.2000.12
[40]Heinz Gall.The TUV approach to functional safety assessment and certification.IEE.2004
[41]F.J.Molina,J.Barbancho.Using industrial standards on PLC programming learning.2007Mediterranean Conference on Control and Automation.Greece.2007