Guidelines for Safe Automation of Chemical Processes

Since 1985, the Center for Chemical Process Safety (CCPS) has been the global leader in developing and disseminating information on process safety management and technology. CCPS, an industry technology alliance of the American Institute of Chemical Engineers (AIChE), has published over 100 books in its process safety guidelines and process safety concepts series, and over 100 training modules through its Safety in Chemical Engineering Education (SACHE).

• List of Figures XiList of Tables XviiAbbreviations XixGlossary Xxiii1 Process Safety and Safe Automation 11.1 Objective 71.2 Scope 91.3 Limitations 91.4 Target Audience 111.5 Incidents That Define Safe Automation 131.6 Overview of the Contents 181.7 Key Differences 212 The Role of Automation in Process Safety 232.1 Process Operations 232.2 Plant Automation 332.3 A Framework for Process Safety 422.4 Risk-Based Design 542.5 Risk Management of Existing Facility 783 Automation Specification 833.1 Process Automation Lifecycle 833.2 Functional Specification 913.3 Designing For Operating Objectives 923.4 Inherently Safer Practices 1043.5 Designing for Core Attributes 1073.6 Control and Safety System Integration 1334 Design And Implementation Of Process Control Systems 1534.1 Input and Output Field Signal Types 1614.2 Basic Application Program Functions 1624.3 Process Control Objectives 1654.4 Process Controller Technology Selection 1724.5 Detailed Application Program Design 1945 Design and Implementation of Safety Controls, Alarms, and Interlocks (SCAI) 2115.1 SCAI Classification 2155.2 Design Considerations 2205.3 SCAI Technology Selection 2446 Administrative Controls and Monitoring 2656.1 Introduction 2656.2 Automation Organization Management 2666.3 Process Safety Information 2696.4 Operating Procedures 2736.5 Maintenance Planning 2916.6 Human and Systematic Failure Management 3036.7 Management of Change 3166.8 Auditing, Monitoring and Metrics 321Appendix A. Control System Considerations 329Appendix B. Power, Grounding, and Shielding 371Appendix C. Communications 391C.1 Communication Classifications 391C.2 Common Communication Network Topologies 395C.3 Communication between Devices 397C.4 Wireless Communication 400C.5 Common Communication Configurations 403C.6 Common Data Communication Issues 407C.7 Process Control and Safety System Communications 412C.8 SCAI Communications 419Appendix D. Alarm Management 423D.1 Alarms 423D.2 Standards and Resources 423D.3 Alarm Management 423D.4 Managing the Safety Aspects Of Alarms 436D.5 Alarm System Performance Benchmarking 437D.6 Alarm Management Software 438Appendix E. Field Device Considerations 441E.1 General Signal Safety 441E.2 Field Device Selection 458E.3 Flow Measurement 465E.4 Pressure Measurement 475E.5 Level Measurement 476E.6 Temperature Measurement 487E.7 On-Stream Process Analysis 489E.8 Automated Valves 493E.9 Electric Motors 504E.10 Steam Turbine Variable Speed Drives 505Appendix F. Sis Equipment Selection 511F.1 Selection Basis 511F.2 Additional Considerations 518Appendix G. Human Machine Interface Design 529G.1 General 529G.2 Operator Interface Standards and Resources 531G.3 Instrument Panels 533G.4 Configurable Operator Workstations 534G.5 Process Alarms 538G.6 Sis Impact on HMI 545G.7 Control-Center Environment 545G.8 Video 546G.9 Operator Interfaces Of Future 546G.10 HMI Considerations Checklist 547Appendix H. Application Programming 551H.1 Software Types 551H.2 Application Program Development 552H.3 Application Programming Languages 554H.4 Application Program Developmental Models 556H.5 Process Control Application Program 557H.6 SCAI Application Program 563Appendix I. Instrument Reliability Program 565I.1 Introduction 565I.2 Tracking Failure 566I.3 Data Taxonomy 568I.4 Data Collection Efforts 569I.5 Failure Investigation 571I.6 Calculation of Failure Rate 572I.7 Verification 576Appendix J. Acceptance Testing Guidelines 581J.1 Acceptance Testing 581J.2 Standards 581J.3 Factory Acceptance Test 582J.4 Site Acceptance Test (SAT) 589Index 597