Definition of Trips, Interlocks, Permissive & Sequences

The purpose of this post is to provide a clear, unambiguous definition of control and protective system functions, which are related to the operational and safety
functions of the DCS, SIS, PLC and Hardwired systems.
Trip
The term Trip refers to an action that is initiated by the control system and which forces a device or devices to a pre-determined state, e.g. Close valve, stop
motor, etc. The SIS or Hardwired systems normally initiate trips, however the PLCs or DCS may also initiate trips provided the necessary independence and SIL
ratings are met. Once a device or devices have been forced to a pre-determined state by the action of a Trip they will remain in that state until the Trip is manually
reset by a conscious operator action.
For example,
High level in a vessel initiates a trip system which stops the pump feeding that vessel, the pump will remain stopped even if the level in the vessel falls to a
safe level.
The Trip must be 'reset' by the operator before the pump can be re-started.
The Trip can only be 'reset' if the level in the tank has fallen to a safe level.
Resetting the Trip will not cause the pump to automatically re-start, however it may be re-started by an operator action or a control system command e.g. part
of a sequence.
The resetting of Trips is a controlled procedure which will only be possible if the operator is logged in and has the necessary access rights. Under normal
circumstances it shall not be possible to 'override' or `defeat' Trips.
Interlock
An Interlock is in essence a 'self-resetting' Trip. Interlocks are not deemed safety related and can be used for on/off control.
Interlocks are normally initiated by the DCS or PLCs, however if an Interlock is deemed to be safety related it may, depending upon SIL rating, be implemented in
the SIS or a Hardwired system.
An interlock will force a device or devices to a pre-determined state e.g. Close valve, stop motor, etc.
Once a device or devices have been forced to a pre-determined state by the action of an Interlock they will remain in that state until the initiating cause returns to a
'healthy' condition, the Interlock will then be automatically removed.
Under normal circumstances it shall be possible to 'override' Interlocks for operational reasons or 'defeat' them for maintenance or other reasons.
Permissive
A Permissive is a particular type of Interlock used to prevent actions taking place until pre-defined criteria have been satisfied, for example prevents a pump starting
until the suction valve is open.
Permissives are normally initiated by the DCS or PLCs, however if a Permissive is deemed to be safety related it may, depending upon SIL rating, be implemented in
the SIS or a Hardwired system.
Once a Permissive has been satisfied and the resulting action implemented it becomes inactive, for example once the suction valve has been opened and the pump
started the Permissive takes no further action, even if the suction valve is closed while the pump is running.
Under normal circumstances it shall be possible to 'override' Permissives for operational reasons or 'defeat' them for maintenance or other reasons.
Sequence
A Sequence is defined as a pre-arranged action or number of actions which are carried out by the control system. Sequences may be initiated by an event or
operator actions.
Sequences may be 'single pass' or 'cyclic'.
The following is an example of a 'single pass' sequence:
An agitated vessel reaches a pre-determined level. The operator initiates a sequence that carries out the following actions:
Stop the feed pump
Close the filling valve
Stop the agitator.
Wait 30 seconds.
Open the discharge valve.
The following is an example of a 'cyclic' sequence:
Low level in a vessel opens the filling valve.
The valve remains open until high level is detected.
On high level the valve closes.
The valve remains closed until low level is detected.
On low level the valve opens and the sequence it repeated.
Combined Functions
It is common for Trip, Interlock, Permissives and Sequences to fulfil combined functions, for example the following pump protection system illustrates how
the same system can perform various functions.
Permissive
Prevent pump starting until suction valve is open.
Interlock
Pump running - suction valve closed-pump stops.
Sequence
High level in vessel-Pump stops
Low level in vessel-Pump starts.
Pump running - suction valve closed - pump stops,
Suction valve re-opened - pump remains stopped.
Operator resets trip.
Pump available for re-start.

Instrumentation Power Cable Calculation

What is an instrument power cable sizing? Instrument power cable sizing is a calculation of voltage drop across some distance from instrument marshalling
cabinet to field devices. It is needed to make sure that the supply voltage at the field devices is sufficient (within device operating voltage or within specified
requirement). For example, we have a solenoid valve put at 250 meter from marshalling cabinet. This solenoid valve requires a supply voltage 24 VDC. Due to a long
distance separated, the voltage received at solenoid valve will not be 24 VDC. It may be 23.5 VDC, 22 VDC, or even 15 VDC. It depends on the size of cables that
used. So, the purpose of the instrument power cable sizing is to select the appropriate cable size so that the voltage drop received at field devices is within an
acceptable range or within specified requirements. So, how to perform such calculation?
First of all, let's take a look at below circuit.

This schematic is an illustration of equipment that has 1 K OHM resistance and separated far away from the power supply by 100 meter. Let's assume that the
cable has an inherent resistance 1 OHM/meter so that in this case, the resistance from power supply to equipment will be 100 OHM. We can replace the above
schematic with below simplified schematic to calculate the voltage drop received at equipment.

Where,
V = 24 Volt
R1 = 100 OHM
R2 = 1K OHM
R3 = 100 OHM
Now we could look for the equivalent replacement resistor for this 3 resistor.
RTOT = R1 + R2 + R3
RTOT = (100 + 1000 + 100) OHM
RTOT = 1200 OHM
After we calculate the equivalent replacement resistor (RTOT) now we could get the current that flow through this circuit.
I = V / RTOT
I = 24 / 1200
I = 0.02 A
Then we shall go back to above circuit to find the voltage received by the R2 (which is our equipment). VR2 = I * R2
VR2 = 0.02 * 1000
VR2 = 20 Volt
From above calculation we could determine that the voltage drop is 4 volt. Each drop is contributed by R1 and R2 as follows:
VR1 = VR3 = I * 100 = 0.02 * 100 = 2 Volt.
Each resistor (R1 & R3) contribute 2 volt voltage drop.
At actual application we rarely know the resistance of our equipment. What usually specified by manufacturer is only a power consumption at nominal power supply
(can be 24 VDC or 48 VDC). So, how to get the equation to calculate the voltage drop across some distance with using the power consumption data?
From illustration in the part 1, we could express the voltage drop (Delta V) as below:
Delta V = V VR2
Delta V = V I*R2
Because I=V/RTOT then,
Delta V = V ( (V/RTOT) * R2)
We take out the same V so that we could get the following equation,
Delta V = V* (1 (R2/RTOT) )
Since the RTOT = R1+R2+R3 then,
Delta V = V* (1 (R2 / (R1+R2+R3) ) )
Since R1 = R2 = Length of cable (L) * Resistance of cable (Rcable) then,
Delta V = V* (1 (R2 / ((L*Rcable) + R2 + (L*Rcable)) )
Delta V = V* (1 (R2 / ((2*L*Rcable) + R2)
Unfortunately we dont know the R2 of the equipment (but we only know the power consumption), then we should replace this in term of power consumption (P).
R2 = P/I[SUP]2[/SUP]
While I = P/V, then
R2 = P / (P/V)[SUP]2[/SUP]
R2 = V[SUP]2[/SUP] / P
Now we substitute this R2 value to voltage drop equation above.
Delta V = V* (1 ( (V[SUP]2[/SUP] / P) / ((2*L*Rcable) + (V[SUP]2[/SUP] / P) )
Delta V = V* ( ((2*L*Rcable) + (V[SUP]2[/SUP]/P) (V[SUP]2[/SUP]/P)) / (2*L*Rcable) + (V[SUP]2[/SUP]/P) )
Delta V = V* ((2*L*Rcable) / (2*L*Rcable) + (V[SUP]2[/SUP]/P))
While (2*L*Rcable) + (V[SUP]2[/SUP]/P) = (2*L*Rcable) + R2 = RTOT
Then we could simplify the above equation to be:
Delta V = V/RTOT * (2*L*Rcable)
Delta V = I * (2*L*Rcable)
Where,
Delta V = Voltage drop across some distance (Volt)
I = electric current (Ampere) = P/V
L = Length of cable (km or m)
Rcable = OHM/km or OHM/m
Usually Rcable represents in OHM/km rather than in OHM/m. And length of cable represents in m. In this case the voltage drop equation will be:
Delta V = (I * 2*L*Rcable) / 1000

Lets take some example.

We have a solenoid valve put at distance 250 meter from the system cabinet (power supply putted). This solenoid valve has a power consumption 5 watt@24
VDC. We need to check what cable size that can be used with the requirement of voltage drop must not exceed 5% at solenoid valve terminal. The following example
cable data will be used:
Cable Cross Sectional Area
Rcable
1.0 mmsq
20 OHM/km
1.5 mmsq
15 OHM/km
2.5 mmsq
10 OHM/km
The calculation:
Calculate the electric current:
I = P/V = 5 watt / 24 V = 0.2083 A
Calculate the voltage drop by using formula:
Delta V = (I * 2*L*Rcable) / 1000 with the preliminary Rcable using the 1.0 mmsq properties.
Delta V = (0.2083*2*250*20)/1000
Delta V = 2.083 Volt
Delta V = 2.083 Volt / 24 Volt *100%
Delta V = 8.67%
It exceeds our requirement which is 5%. So using 1.0 mmsq cable isnt sufficient for our application. Lets try with 1.5 mmsq cable.
Delta V = (0.2083*2*250*15)/1000
Delta V = 1.56 Volt
Delta V = 1.56Volt / 24 Volt *100%
Delta V = 6.5%
By using 1.5 mmsq cables it still exceed the requirement. Lets try again with 2.5 mmsq cable, looks like this cable will suit for this application.
Delta V = (0.2083*2*250*10)/1000
Delta V = 1.04 Volt
Delta V = 1.04Volt / 24 Volt *100%
Delta V = 4.34% which is less than 5% requirement.
Yes, this 2.5 mmsq cable is suitable for our applications. Thus this cable size will be selected for this application.