The increasing complexity and the capacity of the processes in today’s process engineering industry require more and more semi or fully automatic controls. While the observation of safety regulations is predominant in process engineering, high availability is extremely important in production processes with big capacities.
Plant failures should have little or no consequences at all for people or for the plant itself.
The possible hazard of big industrial plants or in traffic technology lies in the system as a whole. It must be monitored and be put to a clearly defined, safe state with the help of controls. For this reason the functional failure of the control may result in a critical reaction.
Safety-related systems are required e. g. for trains, lifts, presses, elevators, incinerator plants etc, and Burner Management Systems (BMS) of multi-burner process-fired heater unit boilers.
For these projects Triconex was supplied to work in integration to Honeywell TPS DCS through the use of OPC link provided by Matrikon.
Our scope of work in both projects included:
Conceptual design:
1. Define the SIS architecture to ensure the SIL is met; voting 1oo1, 1oo2, 2oo2, 2oo3
2. Define logic solver
3. Verify the conceptual design against the SRS (Safety Requirement Specification)
Develop detailed design including:
1. SIS logic solver
2. Field devices
3. Interfaces
4. System Environment
5. Energy Sources
6. Application logic requirements
Define procedures for the following:
1. pre-start-up acceptance test procedure
2. Start-up
3. Operations
4. Maintenance, including administrative controls and written procedures that ensure
safety if a process is hazardous while an SIS function is being bypassed
5. Training
6. Functional testing to detect covert faults that prevent the SIS from operating
7. SIS testing, including:
o Sensors
o Logic solver
o Final elements (e.g., shutdown valves, motors, etc.)
