Chemical Manufacturing Facility’s Enhanced Hazard Mitigation

EPIC’s tailored solution addressed the immediate safety concerns of the manufacturing facility and provided a sustainable and comprehensive approach to ongoing safety management.

Hygienic Process System Design

Project

Overview

  • Industry: Specialty Chemical (Industrial) 
  • Company Size: 16,000 employees, $13BB annual revenue 
  • Location: Washington, USA 
  • Customer Use Case: SIS (Safety Instrumented System) Controller 

Customer’s

Challenge

A prominent global manufacturer and supplier of chemicals, polymers, and building products, faced a critical challenge at its manufacturing facility in the state of Washington, USA. The nature of their operations, involving highly hazardous chemicals, posed a severe risk of explosions with potential environmental consequences, including the loss of human lives. Recognizing the gravity of the situation, the company identified the need to augment safety measures by implementing a secondary protection system to mitigate the consequences of a potential failure in the primary safety measures. 

Epic

Solution

To address the safety concerns, EPIC Systems took a comprehensive approach starting with a Process Hazard Analysis (PHA). This involved an in-depth examination of every aspect of the manufacturing facility to identify potential hazards and failure points at the manufacturing facility and assigning a risk level to each identified issue. Collaborating closely with the client to understand their risk tolerance and utilizing Layers of Protection Analysis (LOPA), EPIC devised a safety control system that aligned with the specified safety requirements. 

The solution included a fully customized SIS (Safety Instrumented System) that comprised of nearly 30 SIFs (Safety Instrumented Functions), ranging from SIL1 to SIL3 (Safety Integrity Level) to meet the safety specifications and mitigate identified risks. To maintain operational continuity, the design encompassed a control system that seamlessly operated in conjunction with existing equipment.   

EPIC also integrated mechanical components, introducing additional safety devices to enhance the overall safety infrastructure. All components were rigorously wired back to the control system with the correct ratings to ensure system integrity.  

EPIC engineers wrote and implemented code to continuously monitor and observe the SIS (Safety Instrumented System) and established a real-time monitoring system to detect anomalies promptly and enable swift corrective actions. Comprehensive testing protocols were developed and implemented to guarantee the on-going effectiveness of the newly integrated safety measures.  

EPIC’s responsibilities covered a wide scope, including:  

  • Safety Requirements Specification (SRS) 
  • Proof Test Procedures 
  • Updated Piping and Instrumentation Diagrams (P&IDs) 
  • Equipment and Instrument Lists 
  • Instrument Data Sheets 
  • Mechanical and Electrical Bid Packages 
  • Installation Instructions  
  • Electrical Design, Control Panels 
  • Safety PLC and HMI programming 
  • On-site Commissioning 
  • Turnover Document Package 

Project

Impact

Risk Mitigation: The implementation of the SIS (Safety Instrumented System) and associated measures significantly reduced the risk of catastrophic incidents, creating a safer working environment for the client and its employees.

Enhanced Safety Infrastructure: Strengthened the safety infrastructure by integrating additional mechanical components and safety devices.

Real-time Monitoring and Anomaly Detection: Established a robust monitoring system with real-time data, allowing for the prompt detection of anomalies and immediate corrective actions.

Reliable System Functionality: Validated the functionality and reliability of the SIS (Safety Instrumented System) through rigorous testing protocols.

Clear Installation Guidance: Provided the client with a detailed construction documentation package, ensuring seamless installation and maintenance of the enhanced safety measures. 

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Our Solutions

EPIC Systems is a multidisciplinary engineering integrator specialized in industrial automation for process manufacturers. We deliver solutions in the following areas:

Process Systems

Machine Vision

Robotics

Industrial Automation