INSTRUMENTATION AND CONTROLS FOR SAFETY

Process Instrumentation

Fundamentals of Instrumentation Systems

The operation of many industrial processes involve inherent risks due to the presence of dangerous material like Explosive gases and chemicals. Instrumentation Systems are designed to protect personnel, equipment and the environment by reducing the likelihood (frequency) or the impact severity of an emergency event.

Fundamentals of Instrumentation Systems

The safe state is a state of the process operation where the hazardous event cannot occur. Instrumentation Systems provides safe isolation of flammable or potentially toxic material in the event of a fire or accidental release of fluids

Fundamentals of Instrumentation Systems

Instrumentation system requires a series of equipment to function properly. It must have sensors capable of detecting normal/abnormal operating conditions Instrumentation system receive the sensor input signal(s), make appropriate decisions based on the signal(s), and change its outputs according to user-defined logic. The final element(s) taking action on the process to bring it to a safe state. Support systems, such as power, instrument air, are required for Instrumentation system operation.

Pressure Measurement Devices

Bourdon Tube Gauge

Plant Safety
A chemical plant has several plant safety systems to ensure safe operation of their processes. These can be a combination of the following: Alarm and Annunciators Safety Trips Interlocks Process control systems.

Alarm and Annunciators

Alarms are used to alert operators of abnormal, serious, and/or potentially hazardous, deviations in process conditions. . Alarms are triggered when a process variable moved away from its normal operating conditions Examples : high pressure, high temperature, low level etc.

Safety Trips

A trip system to take action automatically to avert the hazard, such as:shutting down pumps or compressors, cutting off steam supply to reboiler etc

Interlocks
An interlock system is a group of devices arranged to sense an operating limit or an improper sequence of events, and to shutdown the process deviating from normal condition. An interlock system includes various alarm annunciations and trips. The functioning of an interlock system can be achieved using relays.

Process control system

Process control system perform some or all of the following functions: Monitoring, recording and logging of plant status and process parameters; Provision of operator information regarding the plant status and process parameters; Automatic process control for start-up, normal operation, shutdown, and disturbance. i.e. control within normal operating limits.

Basics of Safety and Layers of Protection

Basics of Safety and Layers of Protection

Safety is provided by layers of protection. These layers start with safe and effective process control, extend to manual and automatic prevention layers, and continue with layers to mitigate the consequences of an event. The first layer is the Basic Process Control System The control system itself provides significant safety through proper design of process control.

Basics of Safety and Layers of Protection

The next layer of protection is also provided by the control system and the system operators. Automated shutdown sequences in the process control system combined with operator intervention to shut down the process are the next layer of safety. The third layer is a safety system independent of the process control system. It has separate sensors, valves and logic system. No process control is performed in this system, its only role is safety. Ex :MVWS system

Basics of Safety and Layers of Protection

The fourth layer is an active protection layer. This layer may have valves or rupture disks designed to provide a relief point that prevents a rupture, large spill or other uncontrolled release that can cause an explosion or fire. The fifth layer is a passive protection layer. It may consist of a dike or other passive barrier that serves to contain a fire or channel the energy of an explosion in a direction that minimizes the spread of damage.

Basics of Safety and Layers of Protection

The final layer is plant and emergency response. If a large safety event occurs this layer responds in a way that minimizes ongoing damage, injury or loss of life. It may include evacuation plans, fire fighting, etc. Overall safety is determined by how these layers work together

Examples of I&C systems important to safety

Systems which provide unit/Plant shutdown (trip) initiation; Ex : General Emergency Shutdown ,Unit 12/16 Shutdown, Unit 14 Shutdown, Unit 17 Shutdown switches located at CCR. Systems used to monitor or maintain plant parameters within operational limits important to safety (such as unit 16 cracker pressure control systems) Systems that perform functions important to maintaining safe shutdown conditions, e.g. TEC PCV 101, 12 PCV 61

HAZARDOUS AREA DEFINITIONS

Hazardous area is an area in which an explosive gas atmosphere is present, or likely to be present.

Explosion protection

Explosion protection is the science of designing and developing electrical products for safe use in highly explosive areas

Explosion protection
Introduction Petroleum products and chemicals in the liquid or vapour form, leads to the formation of highly explosive atmospheres due to the leakage of gases and vapours. When these combine with the oxygen in the atmosphere, potentially explosive mixtures comes into accidental contact with an electrical spark or hot surface, with the resulting explosion causing extensive damage to life and property.

Instrumentation Safety (Preventing Fire and Explosion)

Safety can be achieved by removing at least any one of the elements in the environment around instrumentation
.

Combustion Principles
Three basic conditions must be satisfied for a fire or explosion to occur
A flammable, liquid, vapour or combustible dust must be present in sufficient quantity. The flammable liquid, vapour or dust must be mixed with air or oxygen in the proportions required to produce an explosive mixture. A source of energy must be applied to the explosive mixture.

Conditions for explosion

% Concentration
Upper explosive limit Energy: Electrical Heat Mechanical

Lower explosive limit

Hazardous Area Classification and the Selection of Equipment

ELEMENTS OF HAZARDOUS AREA CLASSIFICATION 1. Flammable gas/vapour risk 2. Sources of Ignition 3. Minimum Ignition Energy 4. Classification of Hazardous materials 5. Zone Classification 6. Gas Grouping 7. Temperature Class 8. Types of Protection

Flammable gas/vapour risk

Flammable liquids generally have a low Flash Point. This is the lowest temperature at which vapour is given off at a sufficient rate to form an explosive mixture with air. Therefore liquids with flash points below ambient temperature will automatically release vapour in sufficient quantities to provide an explosive mixture.

Flammable gas/vapour risk

The power of any explosion depends upon the inherent properties of the gas and its concentration in the atmosphere. Not all concentrations of the flammable gas in air will burn or explode. Vapour Density form concentrations between the LEL and UEL ready to explode as soon as a source of ignition is introduced.

Sources of Ignition
Ignition source has two essential characteristics. Temperature :This must be equal to or higher than the ignition Temperature. Energy :The source must supply sufficient energy at a high enough rate, to raise enough gas mixture to the ignition point to start a self sustaining explosion. The different sources of energy : Flames Sparks - electric or percussive Hot surfaces.

Minimum Ignition Energy

GAS

GROUP O. MI IMUM I GNI ION ENERGY I II A II B II 280 jo les 260 jo les 85 jo les 19 jo les

Methane Propane thylene ydrogen

Classification of Hazardous materials

Class 1:Locations are made hazardous by the presence of flammable gases, liquids or vapors. Class 2:Locations are described as hazardous because of the presence of combustible dusts. Class 3:Locations contain easily ignitable fibers or flyings.

Zone Classification
Zone O Areas where an explosive gas atmosphere is continuously present. eg.: inside of containers or reactors. Zone 1 Areas where an explosive gas atmosphere is likely to occur under normal operation. eg.: areas surrounding Zone 0 & areas surrounding drains, discharge equipment. Zone 2 Areas where an explosive atmosphere is not likely to occur in normal operation and if it does it is only for short periods. eg.: areas surrounding flanged gaskets, areas surrounding Zone 0 or Zone 1.

Gas Grouping
Group classifications made based on the energy requirement for causing the explosion.

APPARA TYPE OF US GAS

EIT ER GASES I.S. EQPT AND LIQUIDS APPROVAL REQUIRED arbon di- sulphite arbon monoxide Acetone Hexane aphtha, Ammonia II only II B or II II A or II B II

II II B II A I

Hydrogen thylene Propane Methane

Temperature Class
T Code T1 T2 T3 T4 T5 T6
Max Surface Temp Ignition Temp

450C 300C 200C 130C 100C 85C

>450C > 300C 450C > 200C 300C > 130C 200C > 100C 135C > 85C 100C

Types of Protection
Worldwide, seven different types of protection are currently recognised Ex i : Intrinsic Safety Ex d : Flameproof Ex e : Increased Safety Ex p : Pressurised Ex o : Oil Immersion Ex q : Powder filling Ex n : Non sparking (basically in UK and India)

IEC 60079-11 Intrinsically Safe Marking EEx i

Intrinsically safe circuits do not allow spark or thermal effect to occur under the potentially explosive atmosphere of sub group IIA, II , or IIC

IEC 60079-1 Flame-Proof Enclosure Marking EEx d

This enclosure will contain the pressure of an explosion, and preventing ignition of flammable gas outside the enclosure. Gaps in the enclosure are so small and their lengths are restricted so that any hot gas released through them will have lost its power to cause ignition.

IEC 60079-7 Increased Safety Marking EEx e

A type of protection in which measures are applied with the higher degree of safety. No possibility of high temperature and of the occurance of arc or sparks in the interior & on the external parts of apparatus in the normal service

IEC 60079-2 Pressurized Enclosure Marking EEx p

The formation of a potentially explosive atmosphere inside a casing is prevented by maintaining a positive internal pressure of protective gas in relation to the surrounding atmosphere and by supplying the inside of the casing with a constant flow of protective gas acting to dilute any combustible mixtures.

IEC 60079-6 Oil-Filled Enclosure Marking EEx o

Electrical apparatus or parts of electrical apparatus are immersed in a protective fluid (such as oil), such that a potentially explosive atmosphere existing over the surface or outside of the apparatus cannot be ignited.

IEC 60079-5 Powder-Filled Enclosure Marking EEx q

Filling the casing of an electrical apparatus with a fine granular packing material has the effect of making it impossible for an electric arc created in the casing under certain operating conditions to ignite a potentially explosive atmosphere surrounding the casing.

IEC 60079-15 Type of protection EExn

Electrical apparatus cannot ignite a explosive atmosphere surrounding them (in normal operation and under defined abnormal operating conditions).

IP Code
As defined in international standard IEC 60529, IP Code classifies and rates the degrees of protection provided against the intrusion of solid objects (including body parts like hands and fingers), dust, accidental contact, and water in mechanical casings and with electrical enclosures

Solids (First Digit)

Level 0 1 2 3 4 5 Object size >50 mm >12.5 mm >2.5 mm >1 mm Dust protected Dust tight Effective against No protection against contact and ingress of objects Any large surface of the body, such as the back of a hand Fingers or similar objects Tools, thick wires, etc. Most wires, screws Ingress of dust is not entirely prevented Complete protection against contact No ingress of dust

Liquid (Second Digit)

Level 0 1 2 3 4 5 Testing for vertically falling drops up to 15Vertically dripping water spray at any angle up to 60 from any direction a nozzle (6.3mm) against enclosure from any direction Powerful water jets powerful jets (12.5mm nozzle) against the enclosure from any direction Immersion up to 1 m immersed in water under up to 1 m Immersion beyond 1 m suitable for continuous immersion Protected against Not protected Dripping water Dripping water Spraying water Splashing water Water jets

6 7 8

The Setting of a high pre-trip alarm

Limit at which protection operates

Time for operator to respond to alarm and correct fault

Abnormal Operating Region

Alarm Setting
A

Limit of largest normal operational fluctuation

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