Plant Hazard Analysis and Safety Instrumentation Systems is the first book to combine coverage of these two integral aspects of running a chemical processing plant. It helps engineers from various disciplines learn how various analysis techniques, international standards, and instrumentation and controls provide layers of protection for basic process control systems, and how, as a result, overall system reliability, availability, dependability, and maintainability can be increased.
This step-by-step guide takes readers through the development of safety instrumented systems, also including discussions on cost impact, basics of statistics, and reliability. Swapan Basu brings more than 35 years of industrial experience to this book, using practical examples to demonstrate concepts.
Basu links between the SIS requirements and process hazard analysis in order to complete SIS lifecycle implementation and covers safety analysis and realization in control systems, with up-to-date descriptions of modern concepts, such as SIL, SIS, and Fault Tolerance to name a few. In addition, the book addresses security issues that are particularly important for the programmable systems in modern plants, and discusses, at length, hazardous atmospheres and their impact on electrical enclosures and the use of IS circuits.
1. 1.0. Introduction - p. 1 2. 2.0. Hazard and Risk - p. 4 3. 3.0. Risk Register, Risk Matrix and Risk Ranking - p. 14 4. 4.0. Consequence, PHA and ALARP - p. 32 5. 5.0. Basics of Mathematics - p. 47 6. 6.0. Fault Tolerance and Plant Ageing - p. 57 7. 7.0. Safety Instrumentation - p. 66 8. 8.0. Functional Safety and Safety Integrity Level - p. 75 9. List of Abbreviations - p. 79 10. Chapter II. Evaluation of Hazard and Risk Analysis - p. 83 11. Chapter III. Qualitative Hazard Analysis - p. 169 12. Chapter IV. Guided Word Hazard Analysis - p. 201 13. 1.0. HAZOP Study/Analysis - p. 201 14. 2.0. Failure Mode and Effect Analysis - p. 251 15. List of Abbreviations - p. 299 16. Chapter V. Quantitative Hazard Analysis - p. 303 17. 1.0. Introduction - p. 303 18. 2.0. Event Tree Analysis - p. 305 19. 3.0. Fault Tree Analysis - p. 320 20. 4.0. Layer of Protection Analysis - p. 346 21. 5.0. Quantitative Risk Analysis in Brief - p. 371 22. 6.0. Human Reliability Analysis in Brief - p. 373 23. List of Abbreviations - p. 379 24. Chapter VI. Discussions on Standards for Risk Assessment and Safety Instrumented Systems - p. 385 25. 1.0. Standard Requirements for Risk Assessment - p. 386 26. 2.0. Short Discussion on Standards for Process Hazards Analyses - p. 396 27. 3.0. Batch Controls and Associated Standards - p. 404 28. 4.0. Functional Safety Standards: IEC 61508 - p. 422 29. 5.0. Functional Safety Process Standards: IEC 61511 - p. 443 30. 6.0. Functional Safety Standard: ANSI/ISA-84.00.01 - p. 462 31. List of Abbreviations - p. 464 32. Chapter VII. Safety Instrumentation Functions and System (Including Fire and Gas System) - p. 467 33. 1.0. Safety Instrumented Function, Safety Instrumented System, and Safety Integrity Level Discussions - p. 467 34. 2.0. Failure Modes, Effects, and Diagnostic Analysis and System Integration Issues - p. 512 35. 3.0. Fire and Gas System in Safety Instrumented Systems - p. 517 36. 4.0. Role of Alarm System in Safety Instrumented Systems - p. 537 37. List of Abbreviations - p. 539 38. Chapter VIII. SIL, PE, FGS, and Plant Emergencies - p. 545 39. 1.0. SIL Methods - p. 545 40. 2.0. SIL Policy and Programmable Systems - p. 577 41. 3.0. Fire and Gas - p. 601 42. 4.0. Plant Emergencies - p. 609 43. 4.4. Reliability Issues - p. 613 44. 4.5. Protection Issues - p. 614 45. 4.6. ESD Configuration and HMI - p. 614 46. List of Abbreviations - p. 616 47. Chapter IX. Safety Instrumented System Requirements for Fieldbus and Control Components - p. 621 48. 1.0. General - p. 621 49. 2.0. Safe Field Bus System - p. 629 50. 3.0. Field Sensors for Safety Instrumented Systems - p. 641 51. 4.0. Alarm Systems in Safety Instrumented Systems - p. 650 52. 5.0. Safety Instrumented System Logic Solver - p. 670 53. 6.0. Final Control Elements for Safety Instrumented Systems - p. 682 54. List of Abbreviations - p. 693 55. Chapter X. Instrumentation Safety Implementation and Explosion Protection - p. 699 56. Explanation - p. 699 57. Section 1: IEC 61508/61511 Implementation - p. 700 58. 1.0. Safety Requirement Specification - p. 701 59. 2.0. Certification and Proof Testing - p. 726 60. Section 2: Explosion Protection - p. 738 61. 3.0. Hazardous Area Classification and Electrical Safety - p. 738 62. List of Abbreviations - p. 801 63. Chapter XI. Fault Tolerance, Protection Layer, and System Security - p. 807 64. Chapter XII. Discussions on the Industrial Application of SIS - p. 875 65. Appendix I. Popular Terms and Their Definitions - p. 927 66. Appendix II. Electrical Protection and Enclosure Class - p. 935 67. Appendix III. Simplified Mathematical Equations - p. 957 68. Appendix IV. Little JIL Process Language - p. 965 69. Appendix V. Embedded Control - p. 981 70. Appendix VI. Cost Impact Discussion - p. 1007 71. Index - p. 1021
Plant Hazard Analysis and Safety Instrumentation Systems is the first book to combine coverage of these two integral aspects of running a chemical processing plant. It helps engineers from various disciplines learn how various analysis techniques, international standards, and instrumentation and controls provide layers of protection for basic process control systems, and how, as a result, overall system reliability, availability, dependability, and maintainability can be increased.
This step-by-step guide takes readers through the development of safety instrumented systems, also including discussions on cost impact, basics of statistics, and reliability. Swapan Basu brings more than 35 years of industrial experience to this book, using practical examples to demonstrate concepts.
Basu links between the SIS requirements and process hazard analysis in order to complete SIS lifecycle implementation and covers safety analysis and realization in control systems, with up-to-date descriptions of modern concepts, such as SIL, SIS, and Fault Tolerance to name a few. In addition, the book addresses security issues that are particularly important for the programmable systems in modern plants, and discusses, at length, hazardous atmospheres and their impact on electrical enclosures and the use of IS circuits.
1. 1.0. Introduction - p. 1 2. 2.0. Hazard and Risk - p. 4 3. 3.0. Risk Register, Risk Matrix and Risk Ranking - p. 14 4. 4.0. Consequence, PHA and ALARP - p. 32 5. 5.0. Basics of Mathematics - p. 47 6. 6.0. Fault Tolerance and Plant Ageing - p. 57 7. 7.0. Safety Instrumentation - p. 66 8. 8.0. Functional Safety and Safety Integrity Level - p. 75 9. List of Abbreviations - p. 79 10. Chapter II. Evaluation of Hazard and Risk Analysis - p. 83 11. Chapter III. Qualitative Hazard Analysis - p. 169 12. Chapter IV. Guided Word Hazard Analysis - p. 201 13. 1.0. HAZOP Study/Analysis - p. 201 14. 2.0. Failure Mode and Effect Analysis - p. 251 15. List of Abbreviations - p. 299 16. Chapter V. Quantitative Hazard Analysis - p. 303 17. 1.0. Introduction - p. 303 18. 2.0. Event Tree Analysis - p. 305 19. 3.0. Fault Tree Analysis - p. 320 20. 4.0. Layer of Protection Analysis - p. 346 21. 5.0. Quantitative Risk Analysis in Brief - p. 371 22. 6.0. Human Reliability Analysis in Brief - p. 373 23. List of Abbreviations - p. 379 24. Chapter VI. Discussions on Standards for Risk Assessment and Safety Instrumented Systems - p. 385 25. 1.0. Standard Requirements for Risk Assessment - p. 386 26. 2.0. Short Discussion on Standards for Process Hazards Analyses - p. 396 27. 3.0. Batch Controls and Associated Standards - p. 404 28. 4.0. Functional Safety Standards: IEC 61508 - p. 422 29. 5.0. Functional Safety Process Standards: IEC 61511 - p. 443 30. 6.0. Functional Safety Standard: ANSI/ISA-84.00.01 - p. 462 31. List of Abbreviations - p. 464 32. Chapter VII. Safety Instrumentation Functions and System (Including Fire and Gas System) - p. 467 33. 1.0. Safety Instrumented Function, Safety Instrumented System, and Safety Integrity Level Discussions - p. 467 34. 2.0. Failure Modes, Effects, and Diagnostic Analysis and System Integration Issues - p. 512 35. 3.0. Fire and Gas System in Safety Instrumented Systems - p. 517 36. 4.0. Role of Alarm System in Safety Instrumented Systems - p. 537 37. List of Abbreviations - p. 539 38. Chapter VIII. SIL, PE, FGS, and Plant Emergencies - p. 545 39. 1.0. SIL Methods - p. 545 40. 2.0. SIL Policy and Programmable Systems - p. 577 41. 3.0. Fire and Gas - p. 601 42. 4.0. Plant Emergencies - p. 609 43. 4.4. Reliability Issues - p. 613 44. 4.5. Protection Issues - p. 614 45. 4.6. ESD Configuration and HMI - p. 614 46. List of Abbreviations - p. 616 47. Chapter IX. Safety Instrumented System Requirements for Fieldbus and Control Components - p. 621 48. 1.0. General - p. 621 49. 2.0. Safe Field Bus System - p. 629 50. 3.0. Field Sensors for Safety Instrumented Systems - p. 641 51. 4.0. Alarm Systems in Safety Instrumented Systems - p. 650 52. 5.0. Safety Instrumented System Logic Solver - p. 670 53. 6.0. Final Control Elements for Safety Instrumented Systems - p. 682 54. List of Abbreviations - p. 693 55. Chapter X. Instrumentation Safety Implementation and Explosion Protection - p. 699 56. Explanation - p. 699 57. Section 1: IEC 61508/61511 Implementation - p. 700 58. 1.0. Safety Requirement Specification - p. 701 59. 2.0. Certification and Proof Testing - p. 726 60. Section 2: Explosion Protection - p. 738 61. 3.0. Hazardous Area Classification and Electrical Safety - p. 738 62. List of Abbreviations - p. 801 63. Chapter XI. Fault Tolerance, Protection Layer, and System Security - p. 807 64. Chapter XII. Discussions on the Industrial Application of SIS - p. 875 65. Appendix I. Popular Terms and Their Definitions - p. 927 66. Appendix II. Electrical Protection and Enclosure Class - p. 935 67. Appendix III. Simplified Mathematical Equations - p. 957 68. Appendix IV. Little JIL Process Language - p. 965 69. Appendix V. Embedded Control - p. 981 70. Appendix VI. Cost Impact Discussion - p. 1007 71. Index - p. 1021
