Process Control and Safety Systems

IJK & team Process Control and Safety Systems
Process Control and

Safety Systems
In Jumanda K
Layers of Protection for High Reliability
EMERGENC Y RESPO NSE Strength in Reserve

• BPCS - Basic process
C O NT AINMENT
A control System
U
RELIEF • Alarms - draw attention
T
O • SIS - Safety intrumented
SIS
M system to stop/start
equipment
A LA RMS A
T • Relief - Prevent excessive
BPC S I pressure
O • Containment - Prevent
N materials from reaching,
workers, community or
environment
• Emergency Response -
evacuation, fire fighting,
health care, etc.
IJK & team 2
Organized by : Fiqry Jaya Manunggal, PT 1

IJK & team 3
Safety Instrumented Function

Safety & Layers of Protection
IJK & team 4

Independent Protection Layers
M P la nt an d /o r
I E m er gen c y Em er g e n c y r e sp o n s e la yer
T Res p o ns e
I
G
Di ke P ass i ve p r o tec tio n la y er
A
T
I
Rel ie f val ve,
O Ru p tu re d isk A c tive p r o tecti o n l a yer
N
S af et y E m e rg en cy S h u t
In st ru m e n te d I so late d p r o tecti o n la ye r
S yst em D ow n a ct io n
T r ip l e v e l a l ar m
P
R O p era to r W ild pr oc es s
E In te rv en t i on
P ro ce ss c o n tro l lay e r
p ar a m e t e r
V H ig h le v e l a l a r m
E H ig h le v e l
N Bas ic
T P roc es s P ro c e s s
Co n tro l v a lue P ro ce ss c o n tro l lay e r
I
S yst em
N o rm a l b e h avi o r
O L ow l e v e l
N P la nt
Des ig n
IJK & team 5

Key Concept in process Safety: REDUNDANCY
SAFETY STRENGTH IN DEPTH !

Seriousness
of event
Divert material safely
RELIEF SYSTEM
Stop the operation of part of process

SAFETY INTERLOCK
SYSTEM Four
independent
Bring unusual situation to attention protection
ALARM SYSTEM of a person in the plant layers (IPL)
In
BASIC PROCESS Closed-loop control to maintain process automation
CONTROL SYSTEM within acceptable operating region
PROCESS
IJK & team 7
BPCS
• First line of defense
• Menjaga agar kondisi proses tetap berada di daerah aman,
yaitu di daerah set point.
× Mengendalikan variable yang tak stabil
× Mengendalikan variabel yang terkait dengan keselamatan
× Mengawasi variabel stabil yang cenderung berubah secara
cepat
Contoh: tekanan pada keluaran atas proses flash
× Mengawasi variabel yang berubah dalam waktu yang lama
Contoh: korosi, erosi.
IJK & team 8

BPCS Elements
Secara umum terdiri dari 4 elemen pokok:

1. Elemen Proses (Controlled System)
2. Elemen Pengukuran (Measuring instrument)
3. Elemen Kendali (Controller)
4. Elemen Kendali Akhir (Final control element)
Concepts Instrumentation and Control System - IJK 9
Close Loop Process Control

Industrial Close Loop Process Control – Elements
Untuk element proses control secara industrial, selain empat

elemen pokok yang disebutkan sebelumnya, juga terdapat
elemen-elemen berikut ini:
Process
Measuring instrument
Transmitter
Transmission lines
Controller
Transducer
Final control element
Close Loop Process Control - Example
F in , Tin Stirrer Level

recorder
Temperature TE
recorder
Controller
Desired
LT value Hs
Controller Fout, Tout

CV
CV
Desired
value T s Condensate
Steam
Transmission lines
F st, Tst

Dimanakah BPCS ditempatkan pada proses

ini..??
F1
IJK & team 13
Tekanan dapat
berubah secara
cepat, sehingga
harus dilakukan
kontrol
Level tidak stabil,

sehingga harus
dilakukan kontrol
F1
IJK & team 14

Alarms
• Ketika set point terlampaui, maka sistem alarm akan aktif.
• Sistem alarm hanya bersifat pemberitahuan dengan
memperlihatkan visual indikasi
• Tidak ada aksi yang otomatis, setiap kejadian memerlukan
pertimbangan dari operator
• Tingkat prioritas keamanan
HIGH : beresiko tinggi untuk manusia atau alat
MEDIUM : kerugian materi, butuh pengawasan
LOW : dapat diinvestigasi jika tersedia waku
IJK & team 15
Dimanakah alarm ditempatkan pada proses ini..??
F1
IJK & team 16

Tekanan dapat
mempengaruhi PAH
sistem
keamanan
Level rendah
rusak pompa,
level tinggi liquid
masuk ke jalur
vapor
F1
LAH
LAL
Terlalu banyak
komponen ringan
menyebabkan AAH
IJK & team
kerugian
17
SIS (Safety Instrumented System)

• Disebut juga PSS (Process Shutdown System) dan ESS
(Emergency Shut Down System) menghentikan proses
meskipun sedang dikendalikan BPCS.
- Mengalihkan aliran ke tempat penampungan sementara
ataupun ke bagian pembuangan
- Menghentikan potensi terjadinya proses yang beresiko
tinggi, contoh: kebakaran
• SIS merespon dengan baik terhadap instrumen yang
mengalami kegagalan (tapi SIS kan butuh instrumen?)
• Lebih agresif dibandingkan dengan BPCS
• Peringatan untuk operator ketika SIS bekerja
IJK & team 18

What is a SIS?
Formal Definition:
SIS – “instrumented system used to implement

one or more safety instrumented functions (SIF).
A SIS is composed of any combination of
sensor(s), logic solver(s), and final element(s)”
(IEC 61511 / ISA 84.01)
Informal Definition:
Instrumented System that detects “out of control”
conditions and automatically returns the process
to a safe state
“Last Line of Defense”
Not basic process control system (BPCS)
IJK & team 19
• IEC 61508 (Ref. 2) does not use the term SIS but
instead uses the term “safety-related system.”
• Practitioners often prefer a more functional

definition of SIS such as: “A SIS is defined as a
system composed of sensors, logic solvers and
final elements designed for the purpose of:
automatically taking an industrial process to a safe state

when specified conditions are violated;
permit a process to move forward in a safe manner when
specified conditions allow (permissive functions); or
taking action to mitigate the consequences of an
industrial hazard.”
IJK & team 20

What makes up a SIS?

Process Process
Input Output
IAS
SIS Program SV
Transmitter Safety
valve
Sensor(s) Logic solver(s) Final Element(s)
IJK & team 21
How SIS are Different from BPCS?
IJK & team 22

IJK & team 23
Safety PLC vs. standard PLC – what’s the difference?
Standard PLC has unknown failure modes – don’t

know how it will fail before it fails
Safety PLC is guaranteed to fail safely to within

certified probability (SIL 1, 2 or 3)
Safety PLC is certified by a 3rd party to international

standards IEC 61508, IEC 61511 – TÜV
Certification includes certificate, report to the

certificate AND operation as per safety manual of PLC
Safety PLC must be configured by person with

appropriate safety competency
IJK & team 24

Where would I need a SIS?
Typical applications for SIS

ESD: Emergency ShutDown System
F&G: Fire and Gas System
BMS: Burner Management System
TMC: Turbo Machinery Control System
HIPPS: High Integrity Pressure Protection System
WHCP: Well Head Control Panel
IJK & team 25
What is a S afety I nstrumented F unction (SIF)?
Formal Definition:
SIF – “function to be implement by a SIS which

is intended to automatically achieve or maintain a
safe state for the process with respect to a
specific hazardous event.” (IEC61511 ISA SP
84.01)
Informal Definition:
Independent safety loop or interlock that

automatically brings process to a safe state in
response to specific initiating events
IJK & team 26

DEFINITION
•In ANSI/ISA-84.00.01-2004 (IEC 61511 Mod),
3.2.71, a safety instrumented function is
defined as a “safety function with a specified
safety integrity level which is necessary to
achieve functional safety.”
• This standard, 3.2.68, defines a safety function
as a ”function to be implemented by a SIS,
other technology safety-related system or
external risk reduction facilities, which is
intended to achieve or maintain a safe state for
the process, with respect to a specific
hazardous event.”
IJK & team 27
SIS versus SIF

SIF
SIS
Logic
Solver
Sensors
Final elements
IJK & team 28

Relief System
• no external power required
• The action is automatic – tidak membutuhkan tenaga
manusia
• Biasanya, tujuannya adalah untuk mengurangi tekanan
- Prevent high (over-) pressure
- Prevent low (under-) pressure
IJK & team 29
SIS tak mampu Standard Relief Method
Safety Relief Method
Valve Rupture Disk
IJK & team 30

Valve
- Relief Valve - liquid systems
- Safety Valve - gas and vapor systems including steam
- Safety Relief Valve - liquid and/or vapor systems
* Tertutup apabila tekanan kembali ke rentang nilai yang aman
(dapat diterima sistem)
• Mereduksi tekanan ketika proses berada dalam kondisi bahaya
dengan cara mengeluarkan udara yang berada di dalam vessel
ataupun yang berada di sepanjang pipa saluran proses.
Conventional
Balanced
IJK & team 31
Keunggulan
• Simple, low cost dan memiliki banyak pilihan desain
• Mengembalikan proses kembali normal dengan cepat
Kelemahan
• Dapat bocor setelah terbuka
• Tidak untuk tekanan yang terlalu tinggi (20000 psi)
• Jika ukurannya tidak sesuai, dapat menyebabkan kerusakan
dan kegagalan (semakin besar valve bukan berarti semakin
aman)
IJK & team 32

Rupture Disk
Rupture Disks / Burst Diaphragms
harus diganti setelah terbuka
Keunggulan
• Tidak ada kerusakan setelah retak
• Dapat melepas volume yang besar dengan cepat
• Dapat digunakan untuk tekanan yang tinggi
• Dapat digunakan untuk material berupa slurry,
kental, dan lengket
Kelemahan
• Shutdown proses ketika akan mengganti rupture disk
• Dapat kehilangan banyak material ketika relief
• Akurasi lebih lemah dibandingkan relief valve
IJK & team 33
Simbol
• Spring-loaded safety relief valve
To effluent handling
Process
• Rupture disc
Process To effluent handling
IJK & team 34

Dimanakah Safety Relief ditempatkan pada proses ini..??
F1
IJK & team 35
drum dapat diisolasi

dengan menggunakan
control valve, diperlukan
pressure relief
Recover tapi tidak perlu
shutdown, gunakan relief
valve
F1
IJK & team 36

Add Relief to the Following System
Positive
displacemen
t pump
37
The positive displacement

pump will be damaged if the
Positive flow is stopped; we need to
displacemen provide relief.
t pump We would like to recover
without shutdown; we select a
relief valve.
38

Why are all

those valves
in the process?
39
The extra “hand”`valves

enable us to isolate and
remove the heat
exchanger without
stopping the process.
The shell side of the heat
exchanger can be
isolated; we need to
provide relief.
We would like to recover
without shutdown; we
select a relief valve.
40

In some cases, relief and diaphragm are used in series

– WHY?
• What is the
advantage of two in
series?
• Why not have two
relief valves
( diaphragms) in
series?
Why is the pressure

indicator provided?
Is it local or
remotely displayed?
Why?
41
In some cases, relief and diaphragm are

used in series – WHY?
Why is the pressure
indicator provided?
If the pressure
increases, the disk has
a leak and should be
replaced.
Is it local or remotely
displayed? Why?
T he display is local to
reduce cost, because
• What is the we do not have to
advantage of two in respond immediately to
series? a failed disk - the
T he disc protects the situation is not
valve from corrosive hazardous.
or sticky material.
T he valve closes when
the pressure returns
below the set value.
42

Structure vent closed
Structure
explosion
IJK & team 43
Material yang keluar harus diproses atau

dibuang dengan baik
To environment Vent steam, air
Holding for later processing Waste water

treating
From
relief
Recycle to process Fuel gas, fuel

oil, solvent
Recover part to process
Immediate neutralization Flare, toxic

IJK & team
materials
44

Containment
• Digunakan untuk mengatasi dampak kejatuhan
atau suatu usaha penyelamatan
• Contoh
–Wadah terapung untuk tangki penyimpanan
–Lokasi dari relief valve dan lubang angin
–Pengalihan pada penyimpanan sementara/ sistem
pengairan
–Managemen safety pada area containment
IJK & team 45
Emergency Responses
• Digunakan untuk mengatasi akibat dari insiden
• Setiap industri atau pabrik harus memiliki ERP
(Emergency Response Plan)
IJK & team 46

Emergency Operations
• Emergency
Keadaan darurat akibat insiden yang terjadi dlm
batas unit perusahaan dan batas kemampuan
aparat unit operasi setempat untuk
menanggulanginya
• Disaster
Bencana yg diakibatkan oleh insiden yg berasal dr
unit operasi atau dr luar (bencana alam) yg
berakibat fatal terhadap aset perusahaan,
pekerja, masyarakat dan lingkungan
IJK & team 47
Tujuan
Menyelamatkan nyawa
Minimasi kerusakan properti, aset perusahaan
Minimasi kerusakan lingkungan
IJK & team 48

Manajemen Keadaan Darurat
EMERGENC Y MA NAGEMENT SY STEM
1. Kebijakan
2. Identifikasi keadaan darurat
3. Perencanaan awal 10. Investigasi dan system
4. Prosedur keadaan darurat CALL OUT pelaporan
5. Organisasi keadaan darurat AND
6. Prasarana keadaan darurat RESPONSE
7. Pembinaan dan pelatihan
8. Komunikasi
9. Inspeksi dan audit
NORMAL PASCA
OPERATION EMERGENCY EMERGENCY
IJK & team 49

Process Control and Safety Systems

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IJK & team Process Control and Safety Systems

Process Control and

Layers of Protection for High Reliability

EMERGENC Y RESPO NSE Strength in Reserve

Organized by : Fiqry Jaya Manunggal, PT 1

IJK & team 3

Safety Instrumented Function

IJK & team 4

Organized by : Fiqry Jaya Manunggal, PT 2

Independent Protection Layers

IJK & team 5

Organized by : Fiqry Jaya Manunggal, PT 3

Key Concept in process Safety: REDUNDANCY

SAFETY STRENGTH IN DEPTH !

Stop the operation of part of process

IJK & team 7

IJK & team 8

Organized by : Fiqry Jaya Manunggal, PT 4

Secara umum terdiri dari 4 elemen pokok:

Concepts Instrumentation and Control System - IJK 9

Close Loop Process Control

Concepts Instrumentation and Control System - IJK 10

Organized by : Fiqry Jaya Manunggal, PT 5

Industrial Close Loop Process Control – Elements

Untuk element proses control secara industrial, selain empat

Concepts Instrumentation and Control System - IJK 11

Close Loop Process Control - Example

F in , Tin Stirrer Level

Controller Fout, Tout

Concepts Instrumentation and Control System - IJK 12

Organized by : Fiqry Jaya Manunggal, PT 6

Dimanakah BPCS ditempatkan pada proses

IJK & team 13

Level tidak stabil,

IJK & team 14

Organized by : Fiqry Jaya Manunggal, PT 7

IJK & team 15

Dimanakah alarm ditempatkan pada proses ini..??

IJK & team 16

Organized by : Fiqry Jaya Manunggal, PT 8

SIS (Safety Instrumented System)

IJK & team 18

Organized by : Fiqry Jaya Manunggal, PT 9

SIS – “instrumented system used to implement

IJK & team 19

• Practitioners often prefer a more functional

automatically taking an industrial process to a safe state

IJK & team 20

Organized by : Fiqry Jaya Manunggal, PT 10

What makes up a SIS?

Sensor(s) Logic solver(s) Final Element(s)

IJK & team 21

How SIS are Different from BPCS?

IJK & team 22

Organized by : Fiqry Jaya Manunggal, PT 11

IJK & team 23

Safety PLC vs. standard PLC – what’s the difference?

Standard PLC has unknown failure modes – don’t

Safety PLC is guaranteed to fail safely to within

Safety PLC is certified by a 3rd party to international

Certification includes certificate, report to the

Safety PLC must be configured by person with

Typical applications for SIS