Addressing the challenges of implementing safety instrumented systems in multi-product batch processes |
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| Institution: | 1. Physics and Electronics Department, Adekunle Ajasin University, Akungba Akoko, 342111, Ondo State, Nigeria;2. Deanship of Graduate Studies, King Fahd University of Petroleum and Minerals, Dhahran, 31261, Saudi Arabia;3. Department of Mathematics, Computer Science Unit, Usmanu Danfodiyo University, Sokoto, Nigeria;4. Institute for Digital Communications, School of Engineering, University of Edinburgh, Edinburgh, EH9 3FG, United Kingdom;5. Computer Science Department, College of Computer Science and Information Technology, Imam Abdulrahman Bin Faisal University, Dammam, PO.Box 1982, Saudi Arabia;1. School of Building Environment Engineering, Zhengzhou University of Light Industry, Zhengzhou, 450002, China;2. Faculty of Resources & Safety Engineering, China University of Mining & Technology (Beijing), Beijing, 100083, China;3. Department of Engineering Management, Henan Technical College of Construction, Zhengzhou, 450064, China;1. Institute of Thermomechanics, Czech Academy of Sciences, Dolejškova 1402/5, Prague, Czech Republic;2. Faculty of Mathematics and Physics, Charles University in Prague, Ke Karlovu 3, Prague, Czech Republic;1. Department of Production and Quality Engineering, Norwegian University of Science and Technology, NO 7491 Trondheim, Norway;2. Batna University, IHSI-LRPI, avenue Chahid Mohamed Boukhlouf, 05000 Batna, Algeria;3. TOTAL Professeurs Associés, 38, rue du Prieuré, 33170 Gradignan, France;1. College of Mechanical and Electronic Engineering, China University of Petroleum, Shandong Qingdao, 266580, China;2. Shenzhen Gas Corporation Ltd. |
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| Abstract: | Adapting the requirements of IEC 61511 to a batch system can be frustrating, particularly for multi-product units. While a Safety Instrumented System (SIS) for continuous operation is often a straightforward detect-decide-act loop, implementing a SIS for a batch system may involve multiple safety functions, time- or state-dependence, intricate calculations, or complex installations. Relationships between the SIS elements and the basic process control system (BPCS) must be tightly managed, providing both for the safety of the unit and its ability to operate without spurious trips or other hindrances. These issues are further complicated when multiple products requiring different functions or setpoints are produced in the same SIS-protected batch unit.This paper will discuss the challenges particular to the design, operation, and maintenance of a SIS in multi-product batch operations and present practical options for successfully resolving the concerns. A key insight into successful adaptation is treating the batch SIS as a “permission” system for the BPCS to operate. Although many items can be addressed through clever engineering practices, sustainable success relies on proactive, robust management of the safety lifecycle. |
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| Keywords: | Safety instrumented systems (SIS) Safety instrumented function (SIF) Basic process control system (BPCS) Safety management Batch process IEC 61511 |
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