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Process Interlocks and Trips - PLC - DCS - RTU - InstrumentationTools
Process Interlocks and Trips - PLC - DCS - RTU - InstrumentationTools
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Trips should not be self resetting unless adequate justification has been
made. Protective interlocks prevent those control actions which might
Rizwan M
initiate a hazard from being undertaken by an operator or process
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control system, and are by nature self-resetting.
Mihir Ra
Qadir M
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Michael
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mouyed
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Independence Loop Co
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Protective systems should be sufficiently independent of the control
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system or other protective systems (electrical/electronic or
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programmable). Where there is an interface between systems (e.g. for
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indication, monitoring or shared components) or shared utilities (e.g.
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power), environment (e.g. accommodation,
or wiring routes)
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management systems (maintenance procedures, personnel), then the
method of achieving independence should be defined, and common
cause failures adequately considered.
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Independence will also be required for protection against systematic
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and common mode faults. Measures may include use of diverse
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technology for different protective systems. Where more than one
E/E/PES protective system is used to provide the required risk reduction
for a safety function, then adequate independence should be achieved
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by diverse technology, construction, manufacturer or software as
necessary to achieve the requires safety integrity level. Rizwan M
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Dependence on utilities
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The action required from the protective system depend upon the nature
of the process. The actions may be passive in nature, such as simple
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isolation of plant or removal of power, or they may be active in that
continued or positive action is required to maintain or restore a safe
Michael
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state, for example by injection of inhibitor into the process, or provision
of emergency cooling.
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Active protective measures have a high dependence upon utilities, and
may be particularly vulnerable to common mode failures. The scope of
the protective system therefore includes all utilities upon which it
depends, and they should have an integrity consistent and contributory
to that of the remainder of the system.
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Measures taken to defend against common mode failure of utilities will
be commensurate with the level of safety integrity required, but may
include standby or uninterruptable/reservoir supplies for electricity, air, CATEGO
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experience. or other
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but you can performance
if you wish.of the safety
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function. Such measures
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Survivability and external in uences
The protective system should be adequately protected against
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environmental influences, the effects of the hazard against which it is
protecting, and other hazards which may be present.
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Environmental influences include power system failure or
characteristics, lightning, electromagnetic radiation (EMR) (IEC 61000),
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flammable atmospheres, corrosive or humid atmospheres, ingress of
water or dust, temperature, rodent attack, chemical attack, vibration
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physical impact, and other plant hazards.
Michael
Degradation of protection against environmental influences during
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maintenance and testing should have been considered and appropriate
measures taken. e.g. Use of radios by maintenance personnel may be mouyed
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prohibited during testing of a protective system with the cabinet door
open where the cabinet provides protection against EMR.
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Proof testing procedures should clearly set out how sensors are
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Maintenance procedures should define how sensors/transmitters are
calibrated with traceability back to national reference standards by use
of calibrated test equipment. RECENT
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Dangerous failures can be minimised by a number of measures
such as:
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Use of ‘fail-safe’ principles so that the actuator takes up the tripped
state on loss of signal or power (electricity, air etc.). e.g. held open,
Mihir Ra
spring return actuator; Loop Co
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RECENT
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Valves should be properly selected for their duty, and it should not
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be assumed that a control valve can satisfactorily perform isolation
functions; Qadir M
Actuators may also include programmable control elements Quick O
(e.g.
SMART instruments) particularly within positioners and variable
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speed drives and motor control centres. Modern motor control
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Logic systems
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Commonly, the logic systems for protective systems are electronic, but
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experience. We'll assume you'reother technology
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but you can opt-out (magnetic
if you wish. Accept or
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fluidic/pneumatic) have been used.
signal lines for detection of wiring (open circuit, short circuit) and
Michael
sensors/actuators (stuck-at, out of range). Such monitoring may initiate
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Utilities CATEGO
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Utilities which are required for the protective system to perform its
safety function may include power supplies such as electricity, air,
inhibitor materials and their propellants, inert gas such as nitrogen, RECENT
cooling water, steam, pilot flames and their gases all of which should be
adequately reliable. Rizwan M
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Measures such as redundancy, and uninterruptable/reservoir supplies,
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and availability monitoring (e.g. loss of air alarm) may be required.
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Confirmation that the designed capacity of reserves is adequate should
be demonstrated by test. Qadir M
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Proof testing
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The probability of failure on demand, or the failure rate of a protective
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its ability to detect previously unrevealed failures of the system. The
proof test interval should therefore be established accordingly, and as a
rule of thumb for low demand systems, should be an order of RECENT
magnitude less than the mean time between failure of the system and
the demand rate. Rizwan M
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Proof test procedures should be available which specify the
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success/failure criteria and detail how the test will be performed safely,
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including any management arrangements, operating restrictions and
competence of personnel. Qadir M
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The tests should be arranged to reveal all dangerous failures which have
Michael
been unrevealed in normal operation including the following measures:Intervie
Operation
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Procedures should be available which detail the operation of the
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protective system including:
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Override management (authorisation, security, recording,
monitoring and review of overrides, reset requirements);
Operating instruction for trips; RECENT
Instructions for response to equipment faults including fault alarms.
(There should be procedural arrangements in place to ensure timely
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repair so that mean time to repair criteria can be met).
Maintenance
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Maintenance instructions;
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Control of spares (segregation of faulty or non-conforming parts,
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identification to prevent interchange of similar parts etc.);
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Competence of maintenance personnel; Sequen
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Operating restriction during maintenance;
Control of software back-ups and memory media (E/EPROMS, floppy
disks, files on hard disks on portable PCs etc.);
Post maintenance reinstatement and proof testing.
For systems where a high diagnostic coverage is claimed, for example Like
Qadir M
Whilst beyond the scope of HS(G)87 ‘Safety in the remote diagnosis of
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manufacturing plant and equipment’, the publication provides a useful
background to the subject. Michael
Intervie