Views: 0 Author: Site Editor Publish Time: 2025-08-13 Origin: Site
In modern industrial production, industrial safety has become a core priority for factories and enterprises. Safety systems play a pivotal role in ensuring operational safety and accident prevention. Among these, Safety Instrumented Systems (SIS) serve as critical components, integrating various safety sensors, safety PLCs, and other core elements. This article provides an in-depth analysis of the working principles and industrial applications of such systems.
Safety Instrumented Systems (SIS) are comprehensive monitoring and management solutions designed to ensure production safety. Their core architecture consists of:
Safety Sensors: Monitor critical parameters such as temperature, pressure, and liquid level in real time.
Safety PLCs: Serve as the data processing and decision-making hub.
Actuators: Execute safety commands as terminal components.
The system operates through a three-tiered control mechanism: sensor data collection → safety PLC analysis and decision-making → actuator response. Modern safety PLCs feature millisecond-level response times, enabling real-time triggering of emergency stops, alarms, and other protective measures.
1. Safety Sensor Technology
Multi-parameter monitoring: Combines detection of vibration, gas concentration, mechanical displacement, etc.
Case study: Chemical reactor temperature monitoring with explosion-proof sensors (±0.5°C accuracy) to prevent thermal runaway risks.
2. Safety PLC Features
Fail-safe architecture: Employs "2oo2" or "3oo2" voting mechanisms.
Self-diagnostic functions: Performs >1,000 hardware self-checks per hour.
Complies with IEC 61508 SIL3 certification standards.
3. Emergency Actuation Units
Explosion-proof emergency stop buttons: Mechanical lifespan >1 million operations.
Industrial-grade alarms: 120 dB sound pressure level with ≥100-meter visibility range.
Oil & Gas Industry
Offshore drilling platforms: SIS enables blowout prevention and automatic shutdown.
Storage tank management: Radar level gauges integrated with safety PLCs achieve 99.99% overflow prevention accuracy.
Power Generation Sector
Boiler protection in thermal plants: Safety PLCs scan pressure data every 50 ms.
Grid substations: Achieve fault isolation and backup power switching in milliseconds.
A multinational chemical group achieved the following after adopting SUPCON TCS-900 safety systems:
80% reduction in incident response time
False actuation rate lowered to 0.001 events/year
TÜV Rheinland SIL3 certification
Industry data: ARC reports indicate the global process safety market will reach $9.8 billion by 2025, with a 6.2% CAGR.
Modern safety systems establish protective shields for industrial production through "sense-decide-act" closed-loop control. As functional safety standards become increasingly stringent, safety instrumented systems are evolving toward intelligent, high-availability solutions.
SUPCON Technology Co., Ltd., an industry leader, has successfully implemented its safety solutions in 30+ countries worldwide, helping clients achieve:
✓ Enhanced safety integrity levels
✓ Intelligent predictive maintenance
✓ Optimized total cost of ownership
For industry-specific whitepapers (e.g., petrochemical/power) or SIL verification services, please contact our functional safety expert team.
