In an era where industrial processes are increasingly complex and safety-critical, effective process safety management is essential to ensure the safe and sustainable operation of chemical and biochemical plants. The purpose of this module is to provide students with a comprehensive understanding of the principles, standards, and practices of safe automation and process control. Students will learn to design, implement, and manage process control systems that minimize risks, enhance safety, and promote sustainability. The module will equip students with the knowledge and skills needed to address real-world challenges in process safety, ensuring they are prepared to contribute to the development of next-generation, safe, and sustainable industrial processes.

The following is indicative of the content to be covered in this module: 1. Introduction to Process Control for Safety and Sustainability: • Incident case studies • Safety culture, process safety and the role of safe automation • Regulatory framework, Standards and Guidelines • Key principles and approaches to safe automation and process control. 2. Safe Process Automation Approaches • Project Life cycle • Automation Specification • Functional Safety Management • Validation V model, FAT, SAT 3. Design and implementation of process control systems, Safety Controls, Alarms and Interlocks (SCAI) • Input and output field signals. • Application programs and process control objectives • Process control technology selection. • SCAI classification, design and selection, Alarm Management • Field device considerations, including ATEX/Classified Areas and ignition control, • Human Machine Interface Design • Inherently safer design • Transient modes of operation - startup, shutdown, emergency shutdown 4. Process Functional Safety and Machine Safety for Electrical, Electronic and Programmable Electronic Safety-related Control Systems - Standards • Overview • ISO-12100 - Risk Assessment and Risk Reduction • IEC-61508 - Functional Safety of Control Systems • IEC-61511 - Functional Safety of Control Systems for Process Industries and SIL Verification • IEC-62061 - Functional Safety of Control Systems for Machine Safety • ISO-13849 - Safety of Machinery and Performance Levels 5. Administrative Controls and Monitoring • Automation organisation management • Process Safety Information • Operating Procedures • Maintenance Planning, Asset Integrity and Reliability • Managing causes of failures, human error • Competency management • Management Of Change • Auditing, Monitoring and Metrics • Physical Security and Cyber / Electronic security

On successful completion of this module, students will be able to: 1. Analyse alarms, interlocks, and Safety Instrumented Functions for process control systems. 2. Evaluate strategies for safe process control and automation to reduce risks of hardware and systematic failures.

On successful completion of this module, students will be able to: 1. Acknowledge the importance of process safety and functional safety in process control and automation (Responsible). 2. Value the principles of safe and sustainable process control and automation in next-generation process industries (Curious)

On successful completion of this module students will be able to: Design and implement process control systems, including Safety Controls, Alarms, and Interlocks (SCAI), by selecting appropriate technology and applying principles of inherently safer design.

The module will be taught via formal lectures, tutorial classes, and group projects, providing students with a blend of theoretical knowledge and practical application. Students will engage in individual and group learning activities, focusing on key areas of process control and automation safety (Curious, Articulate). Projects will be assigned to groups, encouraging collaboration and the development of teamwork and leadership skills (Responsible). Through hands-on activities and case studies, students will apply theoretical principles to real-world challenges, fostering critical thinking and problem-solving skills (Courageous). The module also emphasizes the use of simulation tools to model and validate process control systems, ensuring students develop practical skills in system design and operation (Agile). Recent research findings and developments in functional safety, including advances in Safety Instrumented Systems integration for enhanced process monitoring, and emerging sustainability metrics in control system design will be critically examined through case studies and current industry applications.