Abstract
The modularization of process plants addresses the need for flexible production options in the process industry. In order to maintain the advantages of the adaptability of modular plants, an adaptation of established engineering methods and procedures to their dynamic context of use is required. This paper describes the development and the features of a demonstrator, which makes it possible to investigate aspects of modular plant topology, the design of modular process units, and the functional safety of modules and plants. During the engineering of the modules, modular planning principles are applied and evaluated with respect to the requirements for functional safety and with a strong focus on the modification of safety systems through the exchange of PEAs and FEAs. For the design and modification of the safety systems, a safety life cycle, which meets the requirements of modular automation and takes the provisions of IEC 61508 and IEC 61511 into account, is applied. Practical insights into the construction and the implementation of the distributed Safety Instrumented System as well as the Basic Process Control System are described. In addition to the validation of safety concepts related to the interconnection of Safety Instrumented Functions, the demonstrator is used to study human working environments in modular plants.
Highlights
1.1 Motivation The modularization of process plants addresses the need for flexible production options in the process industry [1, 2]
In this article, we described the implementation of intra- and intermodular Safety Instrumented Systems in the context of modular plants
That the structure of modular process plants according to VDI 2776 can be used advantageously for the flexible adaption of safety systems of Process equipment assemblies (PEAs)
Summary
1.1 Motivation The modularization of process plants addresses the need for flexible production options in the process industry [1, 2]. To ensure the compatibility of the intramodular SISs and the fSOL, standardized description and aligned engineering procedures should be used [15] For this purpose, two harmonized procedure models for the functional safety of PEAs and modular plants were described in the form of Safety-Life Cycles (SLC) in [4]. Recent demonstrators as described in Bittorf et al [21] focus on the automation and interfaces (MTP, Services and POLs) of PEAs. functional safety of modular process plants especially with consideration of adapt and exchange scenarios of PEAs are not mentioned yet
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