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ESD System

ESD system protects against the possibility of a process excursion on topsides process plant, developing into an incident (e.g., loss of containment), and to respond to emergency situations detected by other safeguarding facilities.

This protection is part of a hierarchy provided by a number of layers, typically:

 • Process control, including operator intervention via alarm functions;

• Instrument trip and ESD functions;

• Self-acting mechanical protection such as relief valves or bursting discs.

ESD and related instrumented trip functions are regarded as the primary automatic safeguarding function, and mechanical devices are regarded as secondary protection in the sense that they act after the primary safeguard, though mechanical devices provide a fundamental or ultimate safeguard.

The ESD system works by interpreting a number of input signals from plant measurements, and executing a cause and effect logic to shut down, isolate or vent predetermined items of plant, or to initiate safety systems, according to the nature, location and severity of any hazard. Manual inputs to the system are provided so that installation personnel may shut down the plant in response to conditions not covered by automatic protection.

 

Advantages of KTC ESD System

KTC ESD system ensures the safe production, processing ... and other dealings with flammable substances.

• Prevents the uncontrolled release of flammable or explosive substances

• Prevents the unwanted or unnecessary accumulation of combustible flammable or explosive substances

• Detects all defined events which may require an emergency response

• Gives warning of an emergency

• Appropriately measures with a view to limiting the extent of an emergency, including fire and explosion.

• Appropriately measures with a view to protecting person the installation during an emergency from the effects of fire and explosion.

• Provides emergency shutdown initiated from a control point.

Due to the importance of an emergency shutdown system in a plant, KTC offers its solution as KTC ESD system, fundamentally based on a full redundant programmable safety system provided by PILZ Germany which is called PSS3000 which fully complies with SIL3, AK6.  

 

ESD System Features

Some of the main features of KTC ESD system are as follows:

• Complying with all requirements of Safety Integrity Level (SIL) 3.

Modulating control systems to contain normal process deviations; operator intervention to maintain safe and effective production. 

• Capability of execution inter-trips from other systems, most obviously the fire & gas detection system and DCS by implementing similar ‘cause and effect’ logic

• It is designed to implement the process safety intent and perform with the highest availability and survivability. 

• Fully reliable Self-revealing of internal failures in dormant mode and in normal service

• ESD function logic is generated from the overall process design and safety studies, and traditionally is expressed in a matrix which relates ‘causes’ (e.g. sensor inputs) to ‘effects’ (e.g. valve closures). 

• Capability of defining several levels of shutdown related to the nature of the hazard.

Depending on the complexity of the plant, the location, and the nature of the cause, more widespread shutdowns can be defined. As an example for an oil and gas plant, the following levels can be defined:

• Process shutdowns

• Unit shutdown

• Train shutdown

• Production shutdown (with no blowdown)

• Production shutdown (with blowdown)

• Platform shutdown (with power generation shutdown)

• Abandon platform shutdown (with complete electrical isolation)

 

MINIMUM PROVISION OF ESD FUNCTIONS:

The minimum provision of ESD functions that are provided on a typical offshore oil and gas plant are as follows: 

• All sections of a pressure system with a credible connection to a source of pressure

• Process vessels which contain liquid levels should have high and/or low trips on the level.  • Compressors

• Fired vessels

• Pumps

• Shell-tube heat exchangers 

 

Technical Specifications:

• PILZ, PSS3000 for Failsafe applications

• Central processing unit with integral test algorithms and redundant design, for use as part of a modular safety-related system with connection to Safety BUS p®.

• Processing time Typically 0.5 ms for 1000 instructions

• The 3-channel diverse structure with integral test and safety algorithms, Is suitable for applications conforming to EN 954-1, up to category 4, DIN V 19250, 01/89, AK 6 and EN IEC 61508, SIL 3.

• Downloading via the RS232/RS485 programming port through a PC

• Type tested and approved fail-safe modules

• Standard programmable communication interface

• Communication module for connecting to Ethernet

• Modular hardware and software architecture

• Safety BUS P® communication protocol between stations

• I/O self-diagnostic

• Communication/CPU/channel redundancy (TMR)

• Data memory:

    Standard section: 170 kbytes

    Failsafe section: 64 kbytes

• 4-digit display for status and diagnostics

• Programming software PSS WIN-PRO, Windows-based, IL, LD, FBD

• Supports application headers SINEC S5 application protocol, SINEC S7 application protocol, Modbus TCP

• Supports protocols TCP/IP, H1, RFC 1006

• Menu-driven configuration software for the most common PC operating systems

• Supporting nonvolatile memory in the module’s flash memory

• Ethernet connection via twisted pair (RJ45) or AUI (IEEE 802.3)

• Test Connection and status displayed via LEDs

• Complying Standards IEC-287, IEC-529, IEC-61508, IEC-61511, EN 61000-6-2, 04/99, EN 55011, 08/99, EN 60068-2-6, 04/95 

 

Fail-Safe Digital Input Module with Following Specifications: 

• Failsafe in accordance with EN 954-1, 11/94, up to category 3 if no additional test pulses are used

• 32 digital inputs

• Galvanic isolation for a high level of noise suppression

• Pulse suppression 400 µs

• Protection type (EN 60 529, 10/91) IP 20 (installed on module rack)

 

Fail-Safe Digital Output Module with Following Specifications:

• Fail-safe modules type tested and approved by BG and TÜV

• Fail-safe in accordance with EN 954-1, 11/94, up to category 3 if no additional test pulses are used

• 32 digital outputs

• Galvanic isolation for a high level of noise suppression

• Switch off Impulse Max. 300 µs; Switch-on Impulse Max. 300 µs

• Integral protection circuits

• Power supply with integral protection and monitoring circuits for use as part of a modular safety-related system

• Fail-safe modules have type approval

• Whole system is approved by BG and TÜV

• 24 VDC version for PSS 3000 and PSS 3100

• 115/230 VAC version for PSS 3000

• Integral protection and monitoring circuits

 

Module Sub-Rack

• Module rack in a redundant design, used to build up the modular PSS 3000 safety system  

ESD PLC Panel and Marshalling

• Painting: Electrostatic powder coating system, type of paint Epoxy/Polyester, color RAL 7035/32, thickness of painting: 70µm.

• Dimensions: 2100x800x800 mm

• Ingress protection: IP42 for control cubicles

• Type of cubicles: Free standing, hinged doors, indoor mounting, front & rear access

• Air cooled in the Control room`s temperature regulates by air.