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Objectives of Interlock system Pre-requisites & Challenges faced by Interlock designers Methods of System Design Specification Possible Communication Gaps & Prevention
INTRODUCTION
The Interlock system in a Plant or Equipment is governed by Process Criticality & Automation requirement. The Objective Functions of an interlock system can be one or more of the following: PERMISSIVES: Start-Up of a system in a safe, sequential way. TRIPS: Shut-Down of a system for Pre-determined system abnormalities or by Operator decision in a safe, sequential way. SEQUENCE: Providing repetitive system functions in sequence. ANNUNCIATION: Providing Information to the operator by driving devices like lamps, hooters/horns, counters, alarm annunciators & other HMI devices. OPERATION: Providing the desired level of Automation in the Operation of system for convenience of Process Management.
(a) Poor Communication by the Process Engineer: This may arise due to incomplete definition of system requirements / System ambiguously or wrongly defined / missed out functions due to Process engineer not having communicated with Equipment Engineer or assumption that the objective is not achievable. (b) Poor understanding by the control Design Engineer: This may arise due to negligence to understand the requirements in totality / Wrong interpretations or assumptions on the system requirements / Assumption that certain requirements are not achievable due lack of experience or knowledge. (c) Poor Planning and Unsystematic approach: This may arise due to negligence to specify requirements while Procurement of components that are connected to the interlock system eg. Missing out Limit switch requirement or Specifying Wrong Failure position for Shutdown valves, missing out or Specifying Wrong SIL requirement of Transmitters / Valves etc. Points (a) & (b) can be avoided by improving the communication & having more interaction between different Groups. Point (c) can be avoided by adopting a systematic approach.
SYSTEM SPECIFICATION
The role of the Control Design Engineer is to ensure that the Interlock system Designed is true to the system as envisaged by the Process engineer keeping in mind Operators convenience & the problems faced by maintenance engineer. The System design requirements are decided early in the project & communicated through the following Documents which are a Normally part of BDEP (Basic Design Engineering Package) of Plant or Equipment Vendor Documents P&IDs : In most simple cases , the entire Details of the Interlock requirements can be (i) shown in the P&ID
Figure 1a
(ii)
Cause & Effect Matrix: The Cause & effect Matrix is a document which provides the Details of the Interlock Causes & Effects in tabular form. This document has to be viewed in conjunction with interlock details shown in the P&ID.
Figure 1b
(iii)
Control Narrative / Philosophy: For Complex process & equipments, the Control Narrative / Philosophy document is normally provided by the Licensor/Manufacturer which provides the description of the interlock functions & implementation in Clear, Precise & Easy to Understand Language.
Figure 1c
(iv)
Logic Diagrams: For Equipments & Process unit, sometimes the Logic Diagram is provided by Manufacturer/Licensor. When provided, the same should be insisted to be
in line with ISA symbols (ISA S5.2) & thoroughly reviewed by the control Design Engineer to ensure that sufficient level of Clarity is provided.
(v)
Figure 1d I/O List : The I/O List Document provides the I/Os namely AI , DI , DO & AO for the Interlock system which is usually the PLC (Programmable Logic Controller) or DCS (Distributed Control system).
Figure 1e (vi) Alarm & Set point Summary: The Alarm & Set point Summary document provides the set points for Alarms & Trips used in the Interlock system including the Range & Engineering Units. In many cases, this document is combined with I/O summary to provide the information in a single document.
Figure 1f