Major-accident prevention
On a COMAH site, control and safety systems are vital layers of protection. They must be designed, tested and maintained so that you and the Competent Authority can rely on them when it counts.
Industry brief
Chemicals
Safe, repeatable control for batch and continuous chemical plant.
What matters
What matters most
Chemical plants handle hazardous substances in batch and continuous processes, often on sites that have grown over decades. Their control and safety systems must hold reactions within safe limits, keep product quality consistent, act correctly when things go wrong, and give you and the regulator clear evidence that major-accident risks are under control.
Safety instrumented systems
Trips and interlocks on reactors, storage and utilities must meet the SIL your hazard study sets, with proof testing and bypass control your team can manage.
Consistent, traceable batches
Recipes and equipment must run the same way every time, with batch records that show what was made, how and when, so off-spec product is caught early.
Change without disruption
Products, recipes and equipment change often. Each change must go through your management-of-change process, be tested before it reaches the plant and leave your documentation up to date.
Solutions
Solutions for Chemicals
On a live chemical site, safety and product quality come first. We work within your permit-to-work and management-of-change procedures, prove new logic and recipes against a simulation of the process before they reach site, and plan cut-overs around your campaigns and shutdowns. You get the design, code and safety documentation to run and maintain the system yourselves.
01Reactor and batch process control
02Raw material handling and dosing
03Distillation, separation and drying
04Tank farms, storage and transfer
05Safety instrumented and interlock systems
06Batch reporting and control room HMIs
How we help
What we bring to Chemicals
Standards-led, fully documented control systems that you own and can support.
Upgrades
Modifications and extensions
Extensions to existing and new systems
In Upgrades UpgradesFunctionality upgrades
New functions on a running system
In Upgrades Virtual CommissioningSequence, interlock and fault testing
Every sequence and fault path tested
In Virtual Commissioning Virtual CommissioningSimulated I/O and plant behaviour
Equipment and process that respond
In Virtual Commissioning Code DevelopmentYour standard, your blocks
To your coding standard and block library
In Code Development Code DevelopmentGreenfield: specification to code
New systems built from the specification
In Code DevelopmentStandards
The standards that shape your project
The standards listed are those most often relevant to control-system work in this sector. Which apply to your project, and how, is agreed with you at specification stage.
| Standard | What it covers | How we work with it |
|---|---|---|
| IEC 61511 | Safety instrumented systems for the process industry, across the whole safety lifecycle. | SIS logic designed and tested against your safety requirements specification and target SILs. |
| COMAH Regulations 2015 | Duties on operators of sites holding dangerous substances to prevent and limit major accidents. | Control and safety systems documented to support your major-accident prevention policy and safety report. |
| DSEAR 2002 and IEC 60079 series | Explosive atmosphere risk assessment and zoning, and the protection concepts for equipment in hazardous areas. | Instruments, panels and wiring specified to suit your hazardous area classification. |
| ISA-88 (IEC 61512) | Batch control: common models and terms for recipes, procedures and plant equipment. | Batch software built from equipment phases and recipes, so new products do not mean rewriting code. |
| EEMUA 191 and IEC 62682 | Good practice and requirements for designing and managing industrial alarm systems. | Alarm philosophy, rationalisation and prioritisation, so operators see what needs action. |
| IEC 62443 | Cyber security for industrial automation and control systems, for owners, integrators and suppliers. | Its zones, conduits and security levels shape how we design networks and remote access. |
Take it with you