Emergency plan for instruments

Purpose: To establish an emergency plan for control system failures in order to handle such failures promptly, effectively, and swiftly, thereby preventing system shutdowns or potential serious damage to equipment caused by control system failures. Scope: These procedures apply to the DCS systems throughout the company, as well as the operators of DCS systems and the personnel responsible for instrument maintenance. Responsibilities: 1. The instrument engineers in the Engineering and Technology Department are responsible for formulating these procedures and participating in their supervision and implementation. 2. The instrumentation team in the Engineering and Technology Department is responsible for the maintenance and management of the DCS system. 3. DCS staff are responsible for assisting in the implementation of this procedure. . Appendix: None. Procedures: 1. The production facilities of our company are equipped with Zhejiang University Zhongkong’s JX-300XP and Yokogawa’s CENTUM CS3000 from Japan. In emergency situations where the control system fails to operate properly while the facilities continue to be in use, emergency measures must be taken to address the issue. The possible scenarios and corresponding countermeasures are outlined as follows: 2. Communication failures and failures of some control stations: 2.1 Partial communication interruptions (some control stations remain functional), which affect the use of those control stations; the following emergency measures can be taken: 2.1.1 DCS operators can use other functional control stations to operate the systems that are still running. 2.1.2 DCS personnel shall carry out the emergency operation plans for their respective positions. 2.1.3 DCS personnel work together with instrumentation technicians to identify issues in the DCS system. 2.2 All operation stations are unavailable (no operation data is displayed, and all communications have been interrupted), which affects all operations and may even lead to a shutdown of the entire plant. The emergency measures are as follows: 2.2.1 DCS personnel shall carry out the emergency operation procedures specific to their respective positions. 2.2.2 Under stable production conditions, even if the communication with the DCS operation station is interrupted, as long as the communication between the control station behind the central control cabinet and the field equipment remains intact, the operation data from before the interruption will be preserved. DCS operators can carry out the necessary emergency actions on site based on this situation. 2.2.3 Bring the system to a safe stop through dispatching and control in emergency situations. 2.3 Operator station freezes: 2.3.1 Operation of the central DCS system: 2.3.1.1 After reporting to the shift supervisor and obtaining permission, switch the relevant monitoring displays running on that computer to another computer for monitoring, until that computer can resume control functions. 2.3.1.2 The restart is carried out by the instrument technician, with supervision from the DCS operator; the computer is forced to restart, and once the system is up and running, the real-time monitoring system (i.e., the DCS monitoring system) starts automatically. 2.3.1.3 On the monitoring screen, click the “User Login” button; in the pop-up dialog box, select the appropriate user for the username (Operator, DCTF Operator), use 1111 as the password, and then click Log In. 2.3.2 Operation of the Yokogawa DCS system: 2.3.2.1 After reporting to the shift supervisor and obtaining permission, switch the relevant monitoring screens displayed on that computer to another computer for monitoring, until that computer can resume control. 2.3.2.2 The restart is carried out by the instrument technician, with supervision from the DCS operator; the computer is forced to restart, and once the system is up and running, the real-time monitoring system (i.e., the DCS monitoring system) starts automatically. 2.3.2.3 Operator privileges are available immediately after entering the monitoring screen. 2.4 Cause analysis: Since the control system’s communication system is designed with redundancy, the possibility of multiple failures occurring simultaneously is very low. The causes of failures are mainly damage to the communication cables and switches due to rodent infestations, as well as damage to individual operation stations; this usually results in partial communication disruptions that have a certain impact on process operations. Normal operation can be restored by implementing the aforementioned emergency measures. 2.5 Preventive measures: Strengthen the inspection of control systems to detect and address issues promptly, thereby preventing accidents from escalating. 3. System power loss: 3.1 The control system uses dual power supplies, so system power loss generally does not occur. 3.2 If the DCS in the control room loses power due to reasons such as UPS failures or faults in the mains supply, the following emergency measures must be taken: 3.2.1 Immediately report the situation to the relevant supervisors; since the entire system is without power, inform the process team to initiate the emergency shutdown procedure, and contact the electrical team to restore power to the control room as soon as possible. 3.2.2 After the electrical team confirms that the power supply is normal, the instrumentation technicians check to ensure that the power supply to each control cabinet and terminal cabinet in the control room is functioning properly, and that all systems have been powered on successfully. 3.2.3 Restart the DCS system. 3.2.3.1 Restart the control station: After confirming that the control station is powered on, check and verify the system’s operation. 3.2.3.2 Restarting the engineer station: After confirming that the engineer station is powered on, log into the system, verify that the control station is also powered on, and check to ensure that the system is operating properly and that all programs are present. If not, restore from the system backup and proceed with installation. 3.2.3.3 Restarting the operation station: Enter the system once the operation station is powered on. 3.2.3.4 Check and confirm that all cards in the communication and control stations are functioning properly. 3.2.4.5 After verification that everything is normal, notify the dispatch team to assist with starting up the operation and ensure continuous service for 24 hours. 3.3 Cause analysis: Prolonged power outages can lead to the depletion of the UPS battery, which may result in such a situation. A UPS failure that causes electrical circuit problems can also lead to such situations. Electrical faults are likely to occur when the electrical circuit experiences large fluctuations. 3.4 Preventive measures: Strengthen routine inspections, identify problems promptly, and notify the dispatching and electrical teams to handle them immediately in order to prevent the expansion of accidents. 4. Fire Incidents 4.1 In the event of a fire at the site, the following emergency measures should be taken: 4.1.1 Immediately report to the relevant supervisors and confirm the situation at the site with the dispatch team, following their instructions regarding whether to press the “Emergency Stop” button on the monitoring system. 4.1.2 If the control room is at risk, press the “Emergency Stop” button and then follow the instructions of the dispatchers to evacuate the control room promptly. 4.1.3 If the fire is minor or already under control, follow the instructions of process professionals when carrying out operations; in the absence of such professionals, carry out partial or complete shutdowns in accordance with the established procedures to ensure a safe and stable shutdown. 4.2 In the event of a fire in the cabinet, the emergency procedures are as follows: 4.2.1 Report the situation immediately to the relevant supervisors; at this point, the personnel at the DCS station will determine, based on the conditions at the control station, what emergency measures need to be taken on site. 4.2.2 DCS personnel may use the available fire extinguishers to put out the fire depending on the situation. If the fire cannot be controlled, they must immediately call for assistance and report the location and details of the fire. 4.2.3 The personnel on duty in the operation area and the maintenance staff on shift constitute the first response team under the emergency plan; they are responsible for reporting incidents immediately and taking emergency actions to prevent the situation from worsening. 4.3 Cause analysis: Fires in control stations are mainly caused by illegal use of open flames, short circuits resulting from damaged cable insulation, and heating due to faults in the control system. 4.4 Preventive measures: Eliminate unauthorized welding operations and conduct inspections on schedule.

Above are the operating procedures for our company’s DCS emergency response plan. Since the document is confidential, it cannot be uploaded; therefore, the entire text is copied below for your reference.