Institute of Measurement and Control. Functional Safety 2016
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Figure 5 Digitalisation in the Process Industries
This latest transition goes by a number of different names, one of which is ”Industry 4.0" which
originates from a project in the high-tech strategy arm of the German government promoting the
computerization of manufacturing. It is one vision of what the next Industrial revolution will be.
The interpretation of exactly what form this “digitalisation” takes differs from one industry to another.
So for discrete manufacturing it may take the form of collaboration between cyber physical systems;
using the internet of things and the internet of services; involving digitalisation of the whole value
chain to achieve increased flexibility and productivity.
For the process industries it will likely involve digitalisation of plant across the whole plant life-cycle
and will incorporate topics such as integrated engineering and integrated operations.
Integrated Engineering
Integrated engineering is characterised by use of a shared, common data model and integrated
engineering toolsets across all disciplines with simulation capability built-in. This integration of
engineering capability will span the plant lifecycle right from initial design of process and plant through
to engineering, commissioning, operation and maintenance.
So what will this mean for functional safety? Studies indicate that over 50% of accidents stem from
failures in specification and design so tools that helps reduce these failures can potentially contribute
to safety. An integrated engineering approach to support all activities throughout the lifecycle can
help minimize systematic failures especially, but not only, those associated with specification and
design.
So for instance, as part of an integrated engineering approach, process equipment suppliers and
automation vendors would supply datasets which would combine with the process design, electrical
design, P & ID’s etc to form a common data model used by all across the lifecycle. Each dataset
would include all relevant engineering parameters and typically also include a 3D model of the piece
of equipment.
From a safety perspective this might mean, for instance, that the pressure rating on a vessel could be
linked in SIS specification to a corresponding trip limit in a SIS. It might not be used to directly set a
trip limit but it could certainly be used to cross check if a trip limit is sensible. If, at some later stage,
there is a proposal to change a trip limit during SIS specification, this linkage could be used to
highlight if the new trip limit is sensible and, if not, a specification error avoided.