SAFETY PROCESS ANALYSIS: PST ON ESD AND ALARM & SAFETY DESIGN & EVALUATION

Looking from the defmition of the word disaster, it is defined as an
unexpected natural or man-made catastrophe of substantial extent causing
significant physical damage or destruction, loss of life or sometimes permanent
change to the natural environment. Putting in a scenario of a very critical process
plant where every action and decision must be analyzed into every minute detail, it
is where even the slightest mistake would have an effect on the major process.
What more if a disaster should occurred in the plant, the effect would have been
unimaginable. In the effort of avoiding such incidence, various countermeasures
had been deployed to make sure that every possible case is handled. Among the
main and early stage preventive device is the Emergency Shutdown Valve (ESD),
place in between the upstream/downstream inventory and the processing plant.
The scope of this project is to develop a reliable and efficient controller
configuration for the ESD to perform Partial Stroke Testing (PST) and Full Stroke
Testing (FST) as per demand. It is important for the controller to ensure the device
to perform as per needed, reducing the risk of accidents and mishaps. In the fast
moving pace of current technology, newer hardware improves the efficiency of the
testing process, thus providing easier insight into the procedure. The use of the
ABB Progranunable Logic Control (PLC) together with its progranuning software
CoDeSys provides clearer view of the procedure. The report also details the
development of the controller function block such as the Proportional Band, PID
and process monitoring that includes Alarm & Safety System. The analysis of an
actual plant, namely the PETRONAS Carigali RESAK Plant is also included,
together with its case study. The findings further demonstrate the importance of
the ESD and the FST/PST procedure gained from effective procedure
progranuning and thorough data analysis.