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Practices Play An Important Role in US-OSHA's Process Safety Management Standard

The document discusses the differences between basic process control systems and emergency shutdown (ESD) systems. It states that ESD systems have additional safety features measured by Safety Integrity Level (SIL) ratings from 1 to 4, with higher ratings requiring more stringent features. ESD systems are designed for safety applications and have specifications that decrease mean time for failures and probability of failure on demand. While modern basic control systems have improved reliability, ESD systems are still preferred by designers for critical safety functions. ESD systems represent the fourth layer of protection in a plant, activating when upsets escalate beyond the control of lower layers including the basic process control system and operator intervention.

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Anuj Gupta
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62 views2 pages

Practices Play An Important Role in US-OSHA's Process Safety Management Standard

The document discusses the differences between basic process control systems and emergency shutdown (ESD) systems. It states that ESD systems have additional safety features measured by Safety Integrity Level (SIL) ratings from 1 to 4, with higher ratings requiring more stringent features. ESD systems are designed for safety applications and have specifications that decrease mean time for failures and probability of failure on demand. While modern basic control systems have improved reliability, ESD systems are still preferred by designers for critical safety functions. ESD systems represent the fourth layer of protection in a plant, activating when upsets escalate beyond the control of lower layers including the basic process control system and operator intervention.

Uploaded by

Anuj Gupta
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© © All Rights Reserved
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RAGAGEPs - Recognized and Generally Accepted Good Engineering

Practices play an important role in US-OSHAs Process Safety Management


standard .

Risk Assessment MEthods

Bow Tie Analysis


FMEA
FTA
HAZOP
JHA
LOPA
PHA
SVA
What-If/Checklist

What is the difference between basic process control system


and ESD (emergency shutdown system) (PESS)?
The difference is the ESD has more safety features than the
normal control system. These features are measured by what is
called SIL (Safety Integrity Level) that identifies where such
system can be used.
Each area in which an ESD system will be used is classified by a
certain SIL level from1 to4.1 being the easiest conditions and4
being the toughest conditions.
In most cases redundancy is mandatory in all levels for an ESD
system with SIL3 level.

ESD is used for safety applications, it's all based on manufacturing techniques
and specifications that will affect finally the MTF (mean time of failures) and
the PFD (Probabilty of Failure on demands).Higher SIL rating loops (3 and up)
will most likely require an ESD system to perform it, while normal controlling
loops (SIL1 &2) can be achieved easily by a normal process controllers.
Although the MTF and the PFD of a DCS has been decreased, and safety loops
can be achieved on some DCS systems, designers still prefer to use special
ESD systems.

In the process plan protection layer, the basic process control system (BPCS) is
part of second protection layer while ESD is the fourth layer of protection layer.
Any upset condition of the process will be re-conditioned by BPCS. The BPCS
includes operator, HMI alarms, monitoring system, etc within operator
supervision. If the upset is escalated then safety instrumented system will take
action to prevent the plant, man, machine and process from damage.. in case
(which we dont want to) the upset is continued.. then mitigation steps shall be
in-place... this is the fourth layer and ESD is part of it.
An Example... tank pressure is slightly above the set point.. then HMI alarm
will be activated allows operator to take action.. however the operator is
sleeping and the automatic function is also not functionin... then the pressure is
tend to increase more and more then already out-of-control.. it means the BPCS
have failed to protect. Next, there is pressure relief valve shall open in such
circumstance... but.. somehow it is not open... then the process shall be turned
down by ESD to prevent damage.

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