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A U T O M A T I O N
PROCESS
3
Provide safe response to critical instrumentation failures - But, we use instrumentation in the BPCS?
5
F1
The pressure will change quickly and affect safety; it must be controlled.
F1
2. Alarm System
Alarm has an anunciator and visual indication
- No action is automated! - require analysis by a person - A plant operator must decide. Digital computer stores a record of recent alarms Alarms should catch sensor failures
2. Alarm System
Common error is to design too many alarms - Easy to include; simple (perhaps, incorrect) fix to prevent repeat of safety incident - One plant had 17 alarms/h - operator acted on only 8% Establish and observe clear priority ranking
- HIGH
- MEDIUM - LOW
F1
10
PAH
A low level could damage the pump; a high level could allow liquid in the vapor line.
F1
LAH LAL Too much light key could result in a large economic loss
AAH
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Extreme corrective action is required and automated - More aggressive than process control (BPCS)
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steam
PC LC
water fuel
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fc = fail closed
15 psig
steam PC LC LS
s
water fuel
fc fc
3. Interlock System
The automation strategy may involve several variables, any one of which could activate the SIS If L123 < L123min; or If T105 > T105max . then, reduce fuel to zero
L123 T105 ..
SIS 100
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Failure on demand
5 x 10-3
5 x 10-3
2.5 x 10-6
2.5 x 10-6
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i/o
sensors
sensors
18
These layers require electrical power, computing, communication, etc. Could these all fail due to a common fault?
PROCESS
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20
Increase in pressure can lead to rupture of vessel or pipe and release of toxic or flammable material - Also, we must protect against unexpected vacuum! Naturally, best to prevent the pressure increase - large disturbances, equipment failure, human error, power failure, ... Relief systems provide an exit path for fluid Benefits: safety, environmental protection, equipment protection, reduced insurance, compliance with governmental code
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Relief Valves
Two types of designs determine influence of pressure immediately after the valve
- Conventional Valve -pressure after the valve affects the valve lift and opening - Balanced Valve - pressure after the valve does not affect the valve lift and opening
Conventional
Balanced
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DISADVANTAGES
- can leak after once being open (O-ring reduces) - not for very high pressures (20,000 psi) - if oversized, can lead to damage and failure (do not be too conservative; the very large valve is not the safest!) 26
Process
Rupture disc
Process
To effluent handling
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F1
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F1
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31
The positive displacement pump will be damaged if the flow is stopped; we need to provide relief. We would like to recover without shutdown; we select a relief valve.
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33
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.
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35
What is the advantage of two in series? The disc protects the valve from corrosive or sticky material. The valve closes when the pressure returns below the set value.
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Structure
vent closed
Structure explosion
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Recycle to process
Immediate neutralization
5. Containment
Use to moderate the impact of spill or an escape
Example
Bund containment for storage tanks Location of relief valves and vents diversion to temporary storage /drain system (following breakage of rupture disk) Safety management in containment areas. Containment building (if applicable)
Summary
EMERGENCY RESPONSE CONTAINMENT RELIEF SIS ALARMS BPCS
1. Inherent design starts at project conceptualization 2. Three main strategy Substitution Intensification Attenuation 3. Six Layers of Protection
Introduction to
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Daftar Pustaka
In Jumanda Petruzella, Frank D, 1996. Industrial Electronics.Glencoe: McGraw-Hill. Pitowarno, Endra, 2005. Serial Buku Robotik: Teknik Disain. Surabaya Tcahjono Anang, Ir, 1997. Pelatihan PLC untuk Instruktur Politeknik seIndonesia. Surabaya: PENS-ITS. OMRON, 1990.Users Manual for C20 Programmable Controller.Jakarta:Kerjasama CEVEST dan JICA. OMRON, 1991.Training Manual for Mini H-type Programmable Logic Controllers.Singapura: May Edition.