Safety Instrumented Systems (SIS) Application Reference List

Following are examples of recent Applied Control Engineering, Inc. (ACE) projects involving SIS. Please contact your ACE representative if you require additional information.

Plant Wide Emergency Shutdown System: Oil Refinery

Redundant PLCs (AB PLC5 via ControlNet), redundant fiber optic network.

Shared responsibilities with the client for different phases of the system life cycle. ACE’s services included:

  • Assisted in Process Hazard Analysis meetings
  • Assisted with the SIS conceptual design
  • Performed the SIS Detail Design (hardware and software) based on client’s Safety Requirements Specification – performed full customer FAT
  • Participated in Pre-Start-up Acceptance Test
  • Participated in Pre-Start Up Safety Review System Start-up
Safety Shutdown System Gas Fired Rotary Kiln: Mining Operation

Honeywell Fail Safe Controllers (FSC) with redundant processors, communication modules and I/O.

Shared responsibilities with the client for different phases of the system life cycle. ACE’s services included:

  • Assisted in Process Hazard Analysis meetings
  • Assisted with the SIS conceptual design
  • Performed the SIS Detail Design (hardware and software) based on client’s Safety Requirements Specification – performed full customer FAT
  • Supervised installation of all control system components
  • Participated in Pre-Start-up Acceptance Test
  • Participated in Pre-Start-up Safety Review
  • System Start-up
Process Safety Interlocks: Phosphate Esters Manufacturing

Fully redundant Moore QUADLOG with ProcessSuite HMI.

Assisted client in the implementation of changes to an existing SIS necessitated by the addition of a new process. Utilized client’s Management of Change Procedures. ACE’s services included:

  • SIS Detail Design – Programming
  • Pre-Start-up Acceptance Testing
  • System Start-up
Burner Management System: Steel Annealing Furnace (4 zone, 48 burners)

Hardwired with PLC (GE 90/70) monitoring for HMI display and diagnostics.

ACE furnished a complete turnkey system design including installation drawings and providing all field and panel hardware and:

  • Developed Safety Requirements Specification
  • Conceptual SIS design
  • SIS Detail Design (hardware and software) – including complete customer FAT
  • Operating and Maintenance Manuals
  • Supervised installation of complete system
  • Pre-Start-up Acceptance Testing
  • Pre-Start-up Safety Review
  • System Start-up
Burner Management System: Tail Gas Incinerator

Hardwired with PLC (AB SLC 5/04) monitoring for HMI display and diagnostics.

Shared responsibilities with the incinerator OEM for different phases of the system life cycle. ACE’s services included:

  • Participated in the Safety Requirements Specification Development
  • Participated in the conceptual SIS design
  • SIS Detail Design
  • Operating Manuals
  • Pre-Start-up Acceptance Testing
  • System Start-up
Compressor Safety Shutdown System: Chlorine Production

Simplex PLC (AB PLC 5/40) with PanelView HMI.

Shared responsibilities with the compressor OEM for various phases of the system life cycle. ACE’s services included:

  • Participated in the Safety Requirements Specification Development
  • Participated in the conceptual
  • SIS design SIS Detail Design
  • Operating Manuals
  • Pre Start-up Acceptance Testing
  • System Start-up
Carbon Dioxide Detection System: Coffee Decaffination

Redundant PLC (AB PLC 3).

ACE assisted the end client with the implementation of the system, including:

  • SIS Detail Design
  • Operating Manuals
  • Pre Start-up Acceptance Testing
  • System Start-up
Compressor Safety Shutdown System: Wet Gas Processing

Simplex PLC (AB ControlLogix) with Panelview HMI.

Shared responsibilities with the compressor OEM for various phases of the system life cycle. ACE’s services included:

  • Participated in the Safety Requirements Spec. Development
  • Participated in the conceptual SIS design
  • SIS Detail Design
  • Operating Manuals
  • Pre Start-up Acceptance Testing
  • System Start-up