Process industries are inherently hazardous, and maintaining safety in processes and operations has become increasingly complex and costly. With both safety and financial concerns being a high priority, those in the process industry sometimes struggle to reconcile them.
This paper will discuss the methods used to ensure that the integration between the safety system and the BPCS DO NOT compromise Functional Independence and define best practices to secure an industrial system and in particular safety systems in this integrated environment.
ABB has taken the lead in the domain of electrical integration with its award-winning Extended Automation System 800xA, enabling intelligent electrical devices to be integrated utilizing the global IEC 61850 standard for control and protection of substation equipment.
This special report, focuses on the convergence of communication protocols and underlying technologies in the arenas of process automation and electrical controls, and how this convergence is allowing a growing number of industrial companies to reduce capital costs and operating expenses even as they improve overall plant reliability and energy efficiency.
A cost breakdown of any major batch project reveals that the a major part of the engineering effort is spent on the coding of the logic and sequences. This applies to the initial purchase price and more so to the ongoing support cost for maintenance, upgrades and modifications. Specifically for the pharmaceutical industry, where procedures must meet Regulatory Compliance (FDA approval), measurable economic benefits can be derived from advanced design methodologies.
Based on the experience of a very large Batch project for a pharmaceutical company, the methodology used to reduce the engineering effort and to support validation and hence obtain Regulatory Compliance are explained. The methodology is based on the generation of prototype software modules and a subsequent copy process to generate the actual software modules for the various parts of the plant. All steps are validated to meet FDA requirements.
This methodology resulted in significant savings during the engineering process. Even higher savings were achieved during a later modification to accommodate a plant change, as the process down time could be minimized.
A.M . Verhagen, Senior Consultant Production Automation, Akzo Nobel Engineering B.V.; H. Stapper, Manager Applications, Foxboro Nederland N.V.