Although conventional standards have required safety systems to use hardware relay interlocks, the Ukishima Plant decided to employ the ProSafe-RS safety instrumented system in order to:
- Achieve safer and more stable operation for their safety interlock, which is comprised of many components
- Improve maintainability for the emergency shutdown system
- Reduce the emergency shutdown system's footprint
The Challenges and the Solutions
To increase high-purity propylene production capacity, the Ukishima Plant enhanced the existing CENTUM CS control system and emergency shutdown system, the latter of which achieved:
- A certified emergency shutdown system
Contrary to conventional relay-based systems that cannot obtain certification to meet IEC 61508/JIS C 0508 functional safety standards, the ProSafe-RS safety instrumented system enabled the construction of an emergency shutdown system that could be certified by a registered certification body.
- Substantial reduction in maintenance work
ProSafe-RS is not the first safety instrumented system for JX Nippon Oil & Energy Corporation and the company was already convinced that the new system would require a lot fewer man-hours for maintenance than relay-based systems.
- System configuration with reduced footprint
The new emergency shutdown system had to be installed in a limited space next to the existing instrument panel, and the compact ProSafe-RS was a perfect solution.
- System scalability
The new system is designed to flexibly accommodate future improvements and extensions.
JX Nippon Oil & Energy Corporation commented:
"We began test runs of the system in December 2005 and it' been fully operational since March 2006. Conventional interlocks use hardware relays. However, we employed the ProSafe-RS safety instrumented system because it is compliant with the IEC 61508/JIS C 0508 functional safety standards.
As safety instrumented systems ensure safety more reliably and are more scalable than general relay-based systems, they will be increasingly employed for emergency shutdown systems in the future. Safety instrumented systems can directly deal with contact inputs/outputs as well as 4-20 mA DC and other analog signals from transmitters. This can eliminate the need for alarm configurators and reduce necessary man-hours for periodic maintenance work.
Our ProSafe-RS system has improved reliability by incorporating redundant CPU and I/O modules to avoid unnecessary trips triggered by system abnormalities, not by true safety concerns. Modbus communications with the CENTUM CS for data monitoring are also redundant.
We feel that safety instrumented systems are becoming essential in emergency shutdown systems in Japan and in other countries, and that we must add corporate value by further strengthening plant safety."
Bulk & Petrochemical
Whether you produce petrochemicals, inorganics or intermediates, chemical companies are under cost and margin pressures to deliver products in a timely and efficient manner while maintaining safe and compliant operations. Additionally, chemical companies need to adjust to fluctuating feedstock and energy prices and to provide the most profitable product mix to the market.
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Chemical plants rely on continuous and batch production processes, each posing different requirements for a control system. A continuous process calls for a robust and stable control system that will not fail and cause the shutdown of a production line, whereas the emphasis with a batch process is on having a control system that allows great flexibility in making adjustments to formulas, procedures, and the like. Both kinds of systems need to be managed in available quality history of product, and to be able to execute non-routine operations. With its extensive product portfolio, experienced systems engineers, and global sales and service network, Yokogawa has a solution for every plant process.
Petrochemical companies’ needs are extremely diverse. To come out ahead in today’s highly competitive marketplace, producers are striving to improve quality and productivity. Yokogawa provides tailor-made solutions for these needs based on its long and wide-ranging experience in this field.
Related Products & Solutions
SIS (Up to SIL 3) ProSafe-RS
The ProSafe-RS is a Safety Instrumented System that is certified by the German certification organization (TÜV) to meet Safety Integrity Level (SIL) 3 specified in IEC 61508.
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