CERN Accelerating science

Safety is likely the most critical concern in many process industries, yet there is a general uncertainty on the proper engineering to reduce the risks and ensure the safety of persons or material at the same time as providing the process control system. Some of the reasons for this misperception are unclear requirements, lack of functional safety engineering knowledge or incorrect protection functionalities attributed to the BPCS (Basic Process Control System). Occasionally the control engineers are not aware of the hazards inherent to an industrial process and this causes an incorrect design of the overall controls. This paper illustrates the engineering of the SIS (Safety Instrumented System) and the BPCS of the plasma vapour controls of the AWAKE R&D; project, the first proton-driven plasma wakefield acceleration experiment in the world. The controls design and implementation refers to the IEC61511/ISA84 standard, including technological choices, design, operation and maintenance. Finally, the publication reveals the usual difficulties appearing in these kind of industrial installations and the actions to be taken to ensure the proper functional safety system design.