Devices interlock

Install level device interlocked to prevent overfill... 

Sequence control of process operations, and recipe/batch management and tracking. Alarm and device interlocking (often in addition to separate hard-wired systems). Event and alarm recording, and historical trend recording of process variables. 

The accept and downgrade buttons are interlocked with a sensor device, so that a block must be scanned at least once before the block can be accepted and loaded out by the operator This function will however always be overruled by the programmed safety time limit, which will automatically reject and outload the block when the allowed exposure time has elapsed. 

Normal Operation. The designer of a chemical plant must provide an adequate interface between the process and the operating employees. This is usually accompHshed by providing instmments to sense pressures, temperatures, flows, etc, and automatic or remote-operated valves to control the process and utility streams. Alarms and interlock systems provide warnings of process upsets and automatic shutdown for excessive deviations from the desired ranges of control, respectively. Periodic intermption of operations is necessary to ensure that instmments are properly caUbrated and that emergency devices would operate if needed (see Flow measurement Temperaturemeasurement). 

Where hazardous conditions can develop within a process, a protective system of some type must be provided. Sometimes these are in the form of process hardware such as pressure rehef devices. However, sometimes logic must be provided for the specific purpose of taking the process to a state where the hazardous condition cannot exist. The term safety interlock. system is normally used to designate such logic. 

An interlock is a protec tive response initiated on the detection of a process hazard. The interlock system consists of the measurement devices, logic solvers, and final control elements that recognize the hazard and initiate an appropriate response. Most interlocks consist of one or more logic conditions that detect out-of-hmit process conditions and respond by driving the final control elements to the safe states. For example, one must specify that a valve fails open or fails closed. 

The potential that the logic within the interlock could contain a defect or bug is a strong incentive to keep it simple. Within process plants, most interlocks are implemented with discrete logic, which means either hard-wired elec tromechauical devices or programmable logic controllers. 

The logic for the safety interlock, including inputs from measurement devices and outputs to ac tuators. 

These tests must encompass the complete interlock system, from the measurement devices through the final control elements. Merely simulating inputs and checking the outputs is not sufficient. The tests must duplicate the process conditions and operating environments as closely as possible. The measurement devices and final control elements are exposed to process and ambient conditions and thus are usually the most hkely to fail. Valves that remain in the same position for extended periods of time may stick in that position and not operate when needed. The easiest component to test is the logic however, this is the least hkely to fail. 

Rake drive controls protec t the drive mechanism from damage and usually incorporate an alarm to indicate high torque with an interlock to shut down the drive at a higher torque level. They can have an automated rake raising and lowering feature with a device to indicate the elevation of the rakes. 

For filter boxes, provide remote and automatic filter box lid closing on trip of appropriate fire detection device. Fire detection device may also be interlocked to stop solvent feed, trip deluge internal to filter box and/or trip inert gas blanket for filter box (caution, be aware inert gas is a potential asphyxiation hazard)... 

The assessor should also find out whether an effective testing program is in place to help ensure the serviceability of process measurement equipment. The successful toller should have an established calibration program to address the accuracy of critical measurement equipment. Safety critical process parameters should be monitored and critical process equipment should automatically interlock when monitoring instrumentation detects safety critical deviations. Interlocks should either facilitate a remedy to the critical deviation or bring the process to the zero energy state. These instruments and interlocking devices should be routinely tested to ensure operational reliability. 

Does the facility have a program for regular inspection and testing of process safety valves and other process safety devices including interlocks ... 

This lest is conducted to establish the satisfactory functioning of mechanical parts, such as switching devices and their interlocks, shutter assembly, draw-out mechanisms and interchangeability between identical draw-out modules, A brief procedure to test these features is as follows. 

The interlocks should be set in the intended position to prevent operation of the switching device and insertion or withdrawal of the removable parts. Fifty attempts must be made to operate the switching device and removable parts inserted and withdrawn 25 times each. 

Although many engineers provide only the minimum adequate vessel design to minimize costs, it is inherently safer to minimize the use of safety interlocks and administrative controls by designing robust equipment. Passive hardware devices can be substituted for active control systems. For example, if the design pressure of the vessel system is higher than the maximum expected pressure, an interlock to trip the system on high pressure or temperatures may be unnecessary. 

Process control and safety shutdowns must be provided during all modes of operation, not only in the RUN mode. Other modes will require a BPCS configured for the mode operating algorithm and very likely a different set of safety interlocks must provide appropriate protection. Hardwire devices, like timers or software logic, can be used to actuate the SIS pertinent to the operating mode. 

In the UK. interlock is used to desciibe a device that prevents someone opening one valve while another is open (or closed). Trip describes an auioniaiic device that closes (or opens) a valve when a temperature, pressure, Jlow. etc., reaches a preset value. 

Vent and purge lines Procedure to indicate how to check if fully purged Ensure training covers symptoms of pressure in line Line pressure indicator at controls. Interlock device on line pressure. 

Heaters and furnaces should also be designed in accordance with standards and codes. Boilers and heating units must be inspected periodically in accordance with codes, insurance requirements and state regulations. Proper controls, interlocks and fail-safe instnunentation must be provided. The heaters should also be provided with sight glasses for flame observation, monitoring devices for flame-out detection, and temperature alarms. 

Electric water heaters typically use two 4,500 watt heating elements. One element is located in the lower part of the tank and provides the bulk of the energy. The other element is located near the top of the tank and is used to quickly heat a small amount of hot water after a large draw empties the tank of hot water. The elements are each controlled by separate thermostats and are interlocked so only one can come on at a time. The thermostats on electric water heaters are snap type devices that are installed directly on the outside of the tank, but inside the jacket. They are located a few inches above the element which they control. 

Safety interlock A safety device designed to ensure that equipment will not operate until certain precautions are taken and set on the equipment. 

Where process, safety, and environmental considerations permit, vacuum protection may be provided by properly sized ever-open vents. Alternatively, active protective devices and systems are required. Vacuum breaker valves designed to open and admit air at a predetermined vacuum in the vessel are commonly used on storage tanks, but may not be suitable for some applications involving flammable liquids. Inert gas blanketing systems may be used if adequate capacity and reliability can be ensured. Where the source of the vacuum can be deenergized or isolated, suitably reliable safety instrumented systems (e.g, interlocks) can be provided. 

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