Development of the functional safety system in primary oil refining

The main objective of this work is to design a Functional Safety System based on a control and measuring devices that ensures the safe and highly efficiency operation of the hydrogen production facility and complies with IEC61508, IEC61511, and IEC60812 international functional safety standards. Providing the proposed project with economically efficient hardware and software is a sub-goal of the work. The objectives set for the designed system have been achieved as follows. The designed Functional Safety Circuits automatically bring the system into a safe state when parameters approach the emergency threshold or in the event of an emergency process violation. They also activate light and sound warning alarms indicating the current condition in the hydrogen production unit. This minimizes the risk of human casualties and environmental damage. As a result of the research, it is suggested that the pressure swing adsorption section of the hydrogen production unit, based on control and measuring devices with functional safety circuits, can operate safely and with higher productivity (producing H2 gas with a purity of 99.9%, lower carbon emissions) and with enhanced reliability. In the pressure swing adsorption unit, two different functional safety circuits have been implemented. These circuits prevent explosive accidents that could result in human casualties and long-term environmental impact. They work independently of the technology process automation control system to mitigate the consequences of such events. With the proper selection of equipment, the frequency of unplanned and planned maintenance work by engineering and technical staff is reduced, ensuring comfortable operation of the equipment. The proposed control and measuring devices-based Functional Safety Circuits prevent system stops based on safe fault signals by applying SIL2 and SIL3 equipment.