Journal of Loss Prevention in The Process Industries, Vol.23, No.6, 784-795, 2010
Integrating switchgear breakers and contactors into a safety instrumented function
In the process industries, electrical circuit breakers are tripped for a variety of reasons including hazard prevention and mitigation. This paper will discuss the application of tripping electrical breakers for process safety reasons. It often occurs that a risk assessment study has determined the need to include the shutdown of a large electric motor as part of a safety instrumented function (SIF). In the process industries, it is common practice to control and protect large horsepower motors (typically 2000 HP and above), with medium-voltage switchgear breakers. Safety instrumented functions that include electric motors utilizing medium-voltage switchgear for tripping have unique final element subsystems, which require specialized knowledge in order to implement correctly. This paper will discuss the design considerations for integrating medium-voltage switchgear used for shutdown of an electric motor into a safety instrumented function. First, an overview of typical low and medium-voltage electrical equipment used for controlling and protecting electric motors will be discussed. Next, a review of generic sourced failure data for medium-voltage switchgear breakers will be presented. Focus will be on the taxonomy used to classify different breaker types and the relevant failure modes and effects used for quantifying performance. Next, specific SIF design details for tripping medium-voltage switchgear breakers will be analyzed in the context of achieving a certain integrity level. Parameters to be considered include hardware fault tolerance requirements, voting, available diagnostics, energize vs. de-energize to trip shutdown circuits, certified equipment vs. proven-in-use, and alternate means of shutdown (including manual intervention and protective relaying). This paper will also analyze the common electrical equipment that is shared among potential protection layers used to trip the same breaker, and determine how much credit can be taken considering common cause failure. Finally, inspection, test, and preventive maintenance (ITPM) of medium-voltage switchgear will be discussed as a means for maintaining the electrical equipment in the "as good as new" condition. (C) 2010 Elsevier Ltd. All rights reserved.
Keywords:Contactor;Circuit breaker;Motor starter;Safety instrumented function;Switchgear;Vacuum interrupter