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SIS & ESD (IEC 61511, 61508) Training - Safety Life Cycle

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DOCUMENT DESCRIPTION
The full course on Safety Instrumented Systems (SIS) and Emergency Shutdown (ESD), in accordance with the IEC 61511 and IEC 61508 standards and boiler/gas turbine control safety instrumented systems, consists of 19 training modules. This document refers to the 4th training module only, Safety Life Cycle. Specific topics covered include:

* Safety Life Cycle Overview
* Phases of the Safety Life Cycle
* Safety Requirement Specification

Upon the successful completion of the full SIS/ESD course (all 19 modules), you will be able to:

* Apply a comprehensive knowledge in safety instrumented systems (SIS) and emergency shutdown in accordance with the IEC 61511 and IEC 61508 standards and boiler/gas turbine control safety instrumented systems
* Differentiate safety instrumented systems, control system, and ESD system
* Review the concepts and requirements of IEC 61511 and IEC 61508 standards
* Determine the safety integrity level (SIL), as well as recognize technology choices and reliability analysis
* Perform proper initial system evaluation and discuss the issues related to field devices
* Explain safety systems engineering and carryout system installation covering factor acceptance testing, validation, site acceptance tests, functional safety assessment, pre-start-up safety review, handover to operations, start-up, and post start-up activities
* Recognize the need for functional testing and define hazards and risks
* Illustrate SIS design for gas turbines, gas compressors, and gas stations, as well as SIS design for waste heat boilers

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SIS & ESD (IEC 61511, 61508) Training - Safety Life Cycle

  1. 1. XRS Consulting Engineers and Project Managers 1 Section 4 Safety Instrumented Systems (SIS) & Emergency Shutdown (IEC 61511 & IEC 61508) and Boiler/Gas Turbine Control Safety Instrumented Systems Section 4 Safety Life Cycle
  2. 2. XRS Consulting Engineers and Project Managers 4 Section 4 Safety Instrumented Systems (SIS) & Emergency Shutdown (IEC 61511 & IEC 61508) and Boiler/Gas Turbine Control Safety Instrumented Systems The purpose of a safety instrumented system (SIS) is to reduce risk from a hazardous process to a tolerable level. Although selecting a safety integrity level (SIL), which we will look at later, is vital to this purpose, an organization must also devote significant effort to supporting safety activities. Safety life-cycle (SLC) is an engineering process designed to optimize the design of the SIS and to increase safety. INTRODUCTION Safety Life Cycle This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/sis-and-esd-iec-61511-61508-training-safety-life-cycle-3077
  3. 3. XRS Consulting Engineers and Project Managers 7 Section 4 Safety Instrumented Systems (SIS) & Emergency Shutdown (IEC 61511 & IEC 61508) and Boiler/Gas Turbine Control Safety Instrumented Systems INTRODUCTION The SLC is a closed-loop process as described in several functional safety standards, including IEC61508 and IEC61511. The Safety Life Cycle process does not end. Its lifecycle tasks are continuously performed while the process is in operation, and especially when the designs are periodically reviewed and process changes occur. Safety Life Cycle This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/sis-and-esd-iec-61511-61508-training-safety-life-cycle-3077
  4. 4. XRS Consulting Engineers and Project Managers 10 Section 4 Safety Instrumented Systems (SIS) & Emergency Shutdown (IEC 61511 & IEC 61508) and Boiler/Gas Turbine Control Safety Instrumented Systems The IEC 60508 and IEC 61511 / ISA 84 safety life-cycles are shown schematically in the next slides Each phase of the overall SLC is divided into elementary activities, and the scope, inputs and outputs are specified for each phase OVERVIEW Safety Life Cycle This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/sis-and-esd-iec-61511-61508-training-safety-life-cycle-3077
  5. 5. XRS Consulting Engineers and Project Managers 13 Section 4 Safety Instrumented Systems (SIS) & Emergency Shutdown (IEC 61511 & IEC 61508) and Boiler/Gas Turbine Control Safety Instrumented Systems The essential details of analyzing, designing, verifying, and documenting are discussed and defined in all safety standards. It is important for an organization to devote extra care to the essential Safety Life Cycle so as to ensure that the desired safety level is achieved. A study of actual causes of industrial accidents, performed by the Health and Safety Executive in the United Kingdom, showed that there are a number of causes. OVERVIEW Safety Life Cycle This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/sis-and-esd-iec-61511-61508-training-safety-life-cycle-3077
  6. 6. XRS Consulting Engineers and Project Managers 16 Section 4 Safety Instrumented Systems (SIS) & Emergency Shutdown (IEC 61511 & IEC 61508) and Boiler/Gas Turbine Control Safety Instrumented Systems Phases of Safety Life Cycle Safety Life Cycle This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/sis-and-esd-iec-61511-61508-training-safety-life-cycle-3077
  7. 7. XRS Consulting Engineers and Project Managers 19 Section 4 Safety Instrumented Systems (SIS) & Emergency Shutdown (IEC 61511 & IEC 61508) and Boiler/Gas Turbine Control Safety Instrumented Systems Safety Life Cycle Modify? Select SIS Technology Select SIS Architecture Determine Test Frequency SIS Detailed Design SIS Installation SIS Commissioning SIS Initial Validation Conceptual Process Design Identify Potential Risks Consequence Analysis Layer of Protection Analysis Develop Non -SIS Layers Determine SIF Target SIL Document Requirements Yes Startup Operation Maintenance Periodic Proof Tests Modifications Decommissioning No Analysis Realization Operation Safety Life Cycle – ISA S84.00.01-2004 Modify? Yes No How much safety do I need? How much safety do I have with my design? How will I keep it safe? This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/sis-and-esd-iec-61511-61508-training-safety-life-cycle-3077
  8. 8. XRS Consulting Engineers and Project Managers 22 Section 4 Safety Instrumented Systems (SIS) & Emergency Shutdown (IEC 61511 & IEC 61508) and Boiler/Gas Turbine Control Safety Instrumented Systems Generally, this step involves conducting a detailed hazard and risk analysis. In the process industries a Process Hazards Analysis (PHA) may range from a screening analysis through to a complex Hazard and Operability (HAZOP) study, depending on the complexity of operations and severity of the risks involved. Analysis Phase PHASES OF SAFETY LIFE CYCLE Safety Life Cycle This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/sis-and-esd-iec-61511-61508-training-safety-life-cycle-3077
  9. 9. XRS Consulting Engineers and Project Managers 25 Section 4 Safety Instrumented Systems (SIS) & Emergency Shutdown (IEC 61511 & IEC 61508) and Boiler/Gas Turbine Control Safety Instrumented Systems The latter involves a rigorous detailed process examination by a multi-disciplinary team comprising process, instrument, electrical and mechanical engineers, as well as safety specialists and management representatives. Detailed cause and effect scenarios are considered and risks quantified for all process functions and operations. If the study determines that the mechanical integrity of a process and the process control are insufficient to protect against the potential hazard, a SIS may be required. Analysis Phase PHASES OF SAFETY LIFE CYCLE Safety Life Cycle This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/sis-and-esd-iec-61511-61508-training-safety-life-cycle-3077
  10. 10. XRS Consulting Engineers and Project Managers 28 Section 4 Safety Instrumented Systems (SIS) & Emergency Shutdown (IEC 61511 & IEC 61508) and Boiler/Gas Turbine Control Safety Instrumented Systems BASIC TANK LEVEL CONTROL WITH OVER PRESSURE RELEASE HAZARD Pump Discharge valve Analysis Phase Safety Life Cycle This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/sis-and-esd-iec-61511-61508-training-safety-life-cycle-3077
  11. 11. XRS Consulting Engineers and Project Managers 31 Section 4 Safety Instrumented Systems (SIS) & Emergency Shutdown (IEC 61511 & IEC 61508) and Boiler/Gas Turbine Control Safety Instrumented Systems A key part of this planning step is developing maintenance and proof-test schedules to ensure any potential failure in the safety equipment can be found and repaired before the system is required to act. Once the conceptual design is completed,the organisation needs to analyze the prospective system to confirm it meets the SIL selected and documented in the SRS. Realisation Phase PHASES OF SAFETY LIFE CYCLE Safety Life Cycle This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/sis-and-esd-iec-61511-61508-training-safety-life-cycle-3077
  12. 12. XRS Consulting Engineers and Project Managers 34 Section 4 Safety Instrumented Systems (SIS) & Emergency Shutdown (IEC 61511 & IEC 61508) and Boiler/Gas Turbine Control Safety Instrumented Systems Operations Phase PHASES OF SAFETY LIFE CYCLE Safety Life Cycle Operation & Maintenance Provide operator and maintenance personnel training Operate according to operation and maintenance planning and procedures Proof test and inspect the system according to written proof test procedures for every SIF Document proof tests and inspections The SIMATIC Safety Matrix provides built-in mechanisms for implementation of secure bypasses/overrides and automatically documents all actions in an events log. This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/sis-and-esd-iec-61511-61508-training-safety-life-cycle-3077
  13. 13. XRS Consulting Engineers and Project Managers 37 Section 4 Safety Instrumented Systems (SIS) & Emergency Shutdown (IEC 61511 & IEC 61508) and Boiler/Gas Turbine Control Safety Instrumented Systems SAFETY REQUIREMENTS SPECIFICATION Safety Life Cycle Safety Requirements Specification (SRS) Identify and describe safety instrumented functions Document target SIL Document functional operation (e.g. control narrative, cause and effect, etc.) Document associated parameters – timing, maintenance bypass requirements, etc. Documentation of the functional operation, cause & effect matrix This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/sis-and-esd-iec-61511-61508-training-safety-life-cycle-3077
  14. 14. XRS Consulting Engineers and Project Managers 40 Section 4 Safety Instrumented Systems (SIS) & Emergency Shutdown (IEC 61511 & IEC 61508) and Boiler/Gas Turbine Control Safety Instrumented Systems The effect of the SRS on each of these steps varies. For a typical grass-roots project, the interaction is illustrated in the next slide with the initial step being "feasibility" and continuing clockwise around the figure. The important point of this illustration is that the SRS is central to the design of the SIS. All activities associated with the SIS either affect or are affected by the SRS. Therefore, the SRS must be developed and reviewed by a team of people with process, equipment, operating, and maintenance experience and knowledge. SAFETY REQUIREMENTS SPECIFICATION Safety Life Cycle This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/sis-and-esd-iec-61511-61508-training-safety-life-cycle-3077
  15. 15. XRS Consulting Engineers and Project Managers 43 Section 4 Safety Instrumented Systems (SIS) & Emergency Shutdown (IEC 61511 & IEC 61508) and Boiler/Gas Turbine Control Safety Instrumented Systems The SRS should include the following requirements: Description of all the SIF necessary to achieve the required functional safety Requirements to identify and take account of common cause failures Definition of the safe state of the process for each identified SIF Definition of any individually safe process states which, when occurring concurrently, create a separate hazard (for example, overload of emergency storage, multiple relief to flare system) SAFETY REQUIREMENTS SPECIFICATION Safety Life Cycle This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/sis-and-esd-iec-61511-61508-training-safety-life-cycle-3077
  16. 16. XRS Consulting Engineers and Project Managers 46 Section 4 Safety Instrumented Systems (SIS) & Emergency Shutdown (IEC 61511 & IEC 61508) and Boiler/Gas Turbine Control Safety Instrumented Systems The SRS should include the following requirements: Maximum allowable spurious trip rate Failure modes and desired response of the SIS Any specific procedure requirements for starting up and restarting the SIS All interfaces between the SIS and any other system (including the BPCS and operators) Description of the modes of operation of the plant and identification of the safety instrumented functions required to operate within each mode The application software safety requirements SAFETY REQUIREMENTS SPECIFICATION Safety Life Cycle This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/sis-and-esd-iec-61511-61508-training-safety-life-cycle-3077
  17. 17. XRS Consulting Engineers and Project Managers 49 Section 4 Safety Instrumented Systems (SIS) & Emergency Shutdown (IEC 61511 & IEC 61508) and Boiler/Gas Turbine Control Safety Instrumented Systems The SRS should include the following requirements: Definition of the requirements for any safety instru- mented function necessary to survive a major accident event, for example, time required for a valve to remain operational in the event of a fire. SAFETY REQUIREMENTS SPECIFICATION Safety Life Cycle This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/sis-and-esd-iec-61511-61508-training-safety-life-cycle-3077
  18. 18. 1 Flevy (www.flevy.com) is the marketplace for premium documents. These documents can range from Business Frameworks to Financial Models to PowerPoint Templates. Flevy was founded under the principle that companies waste a lot of time and money recreating the same foundational business documents. Our vision is for Flevy to become a comprehensive knowledge base of business documents. All organizations, from startups to large enterprises, can use Flevy— whether it's to jumpstart projects, to find reference or comparison materials, or just to learn. Contact Us Please contact us with any questions you may have about our company. • General Inquiries support@flevy.com • Media/PR press@flevy.com • Billing billing@flevy.com

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