CFSE - Certified Functional Safety Engineering I - Participant's Notebook - Exida 2007

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Industrial Accident Primary Causes - HSE HSE study of accident causes involving control systems: Changes after Commissioning 20% ~~··· Specification 44% Om••--• 15% Operation & Installation & Commissioning Maintenance 6% 15% "Out of Control: Why Control Systems go Wrong and How to Prevent Fai/ur~ U.K.: Sheffield, Heath and Safety Executive, 1995 (Ed 2, 2003) """"' Copyright exida.com LLC 2001-2008 39 ~-----------__/ [~____ s_a_fe_t_y_L_if_e_cy_c_l_e_o_b_je_c_t_iv_e_s __ ~] 4 Build safer systems that do not experience as many of the problems of the past 4 Build more cost effective systems that match design with risk 4 Eliminate "weak link" designs that cost much but provide little 4 Provide a global framework for consistent designs (] \ .. I Copyright exida.com LLC 2001-2008 40
Practical results of Implementing SLC Refinery: Hydrogen Manufacturing Unit Source 49% 0 ~ 49%: Safety Functions were over-engineered ~ 4%: Safety Functions were under-engineered (unsafe) ~ 47%: No change Copyright exida.com LLC 2001-2008 41 Practical results of Implementing SLC 0 Total of 5319 loops are considered. At 7 different plants So~NAM 37% ~ 37%: Safety Functions were over-engineered ~ 6%: Safety Functions were under-engineered (unsafe) ~ 57%: No change Copyright exida.com LLC 2001-2008 42
Page 1 and 2: Functional Safety Engineering I \ \
Page 3 and 4: Table of Contents SECTION 1 SECTION
Page 5 and 6: SECTION 1 ,·_ Co"rse Presentation
Page 7 and 8: Functional Safety Engineering 1: Ri
Page 9 and 10: exida Certification S.A. in Switzer
Page 11 and 12: 'r~~lr~ ~ ~\lw'
Page 13 and 14: • 1960's SIS Evolution Hardwired
Page 15 and 16: "S0/90's Safety Design Process" ] P
Page 17 and 18: u IEC 61508 Standard 4 Targets Supp
Page 19 and 20: Safety Instrumented System Function
Page 21 and 22: [ Safety Integrity Level J 0 Safety
Page 23 and 24: [ SIF Sensors J Logic Solver 0 Like
Page 25: [~___ s_e_c_t_io_n_1_:_s_u_m_m_a_r_
Page 29 and 30: 0 [ Safety Lifecycle "Analysis" Pha
Page 31 and 32: Safety Requirements Specification 0
Page 33 and 34: u [ Select Architecture • Objecti
Page 35 and 36: Safety Lifecycle "Operation" Phases
Page 37 and 38: Competency • IEC 61508 Personnel
Page 39 and 40: Certified Functional Safety Expert/
Page 41 and 42: [ Why do companies manage risk? ]
Page 43 and 44: [~_____ ln_d_iv_i_d_u_a_I_R_is_k __
Page 45 and 46: Tolerable Risk Level Example < Matr
Page 47 and 48: [ Risk Reduction using Inherent Ris
Page 49 and 50: S [ Risk Management Standards ] 0
Page 51 and 52: [~ ____ s_e_c_t_io_n_4_:_P_r_o_b_a_
Page 53 and 54: ( Rules of Probability- Venn Diagra
Page 55 and 56: [ Complementary Events 0 4 Compleme
Page 57 and 58: [ Probability Multiplication l 4 Fo
Page 59 and 60: Probability Addition Mutually Exclu
Page 61 and 62: Probability Addition Independent Ev
Page 63 and 64: Probability Addition Three Independ
Page 65 and 66: Probability Addition Three Independ
Page 67 and 68: Rules of Probability Exercises 0
Page 69 and 70: Fault Tree 'AND' Gates Independent
Page 71 and 72: [~_F_re_q_u_e_n_c_y_L_o_g_i_c__] EV
Page 73 and 74: Definition of Hazard 0 ~> A potenti
Page 75 and 76: [~___ T_e_rm __:_ln_c_id_e_n_t_o __
Page 77 and 78:
What Is Process Hazards Analysis? 0
Page 79 and 80:
Recommendations for Effective PHAs
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[~__ s_IF __ D_es_c_r_ip_t_io_n ___
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['-_ld_e_n_ti_fy_in_g_S_I_F_f_ro_m_
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[ Consequence Analysis Methods J f
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---'==[ ===C=o=n=s=e=q=u=e=n=;c_e_M
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l~ __ A __ P_P_Iic_a_t_io_n __ Ex_e
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[ Likelihood Categorization J Likel
Page 93 and 94:
[L ___ E_v_e_nt_T __ re_e_A_n_a_l_y
Page 95 and 96:
Event Tree Drawing Example Result I
Page 97 and 98:
Considering All the Impacts with Ri
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[~ ~] ______ s_e_c_ti_o_n_s_:_s_u_m
Page 101 and 102:
0 ' VJ t T M I I G A T I 0 N p R E
Page 103 and 104:
Example Part 1 - Pipe Rupture LOPA
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Example- Pipe Rupture LOPA Solution
Page 107 and 108:
Using Maintenance and Function Test
Page 109 and 110:
Typical Protection Layers - Basic P
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Typical Protection Layers Mechanica
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[~_______ o_c_c_u_p_a_n_c_v ______
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0 [ SLC - SIL Selection l Process S
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[___ H_o_w_to_A_s_s_ig_n_a_S_IL_~]
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Likelihood Part of the Hazard Matri
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[ Hazard Matrix Procedure 2] 0 41de
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Risk Graph Parameters Parameters Co
Page 125 and 126:
Demand Rate (Likelihood) Parameters
Page 127 and 128:
Risk Graph Example Solution () 4,,
Page 129 and 130:
Frequency Based Targets Assign SIL
Page 131 and 132:
Example 1: Individual Risk Based Ta
Page 133 and 134:
[ Risk Integral Advantages
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0 Cost Benefit Analysis 4 Consideri
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Section 8: Safetv Requirements Spec
Page 139 and 140:
Specification Communication ] How t
Page 141 and 142:
[ More SRS Requirements J 0 4; The
Page 143 and 144:
SRS Format: General Requirements Se
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Example: Plain Text Logic Descripti
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Example: Logic Diagram Create a Log
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[~___ A_v_o_i_d_in_g_S_R __ S_P_r_o
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0 [ Safety Lifecycle" Analysis" Pha
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SECTION 2 Exercises 0 0 Copyright©
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0 7. 8. 9. What measure is used in
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FSE I - Application Exercise 2 Name
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3. A fault tree is shown below. Wha
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FSE I - Application Exercise 5 Name
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1. A rupture disk set to relieve th
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FSE I - Application Exercise 8 Nmne
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Process Diagram: Vent to Safe Locat
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7. What measure is used in LOPA to
Page 171 and 172:
FSE I - Application Exercise 2 Titl
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3. A fault tree is shown below. Wha
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1. No Event 0 2. No Event FIC-01 Fa
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3. A non-operated check valve, with
Page 183 and 184:
. Risk Graph Consequence ~ Co Occup
Page 185 and 186:
Process Description: A "wet" hydroc
Page 188 and 189:
SECTION 3 Additional Resources 0 0
Page 190 and 191:
0 IEC 61508 Overview Report 0 An ex
Page 192 and 193:
Although the standard has been crit
Page 194 and 195:
Safety integrity levels (Sils) are
Page 196 and 197:
Part 3 covers the software requirem
Page 198 and 199:
0 0 This translates into specific r
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0 The first part of the safety life
Page 202 and 203:
safety achieved by the safety-relat
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6. the assigned safety integrity le
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Type A components are described as
Page 208 and 209:
Part 3 requires that a process (suc
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2 the "techniques and measures" nec
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programming languages, detailed des
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support for the analyses, the softw
Page 216 and 217:
There is of course no substitute to
Page 218:
I DATA ON SELECTED PROCESS SYSTEMS
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I DATA ON SELECTED PROCESS SYSTEMS
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I DATA ON SELECTED PROCESS SYSTF.MS
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I DATA ON SEI.ECTED rROCF.SS SYSTEM
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l!b) I [ DATA ON SELECTED PROCF.SS
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0 0
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Functional Safety and Reliability T
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n
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exida Industry Focus • Management
Page 273 and 274:
Introduction of Course Participants
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Sample Data [ ~-----------D_a_to_s
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Discrete Distributions - pdf Distri
Page 279 and 280:
Section 2: Basic Reliability Engine
Page 281 and 282:
Random vs. Systematic Faults Aleato
Page 283 and 284:
Terms Terminos High Demand Mode- ex
Page 285 and 286:
Stress- Strength: Failures Esfuerzo
Page 287 and 288:
IEC 61508 Key Variables: 1. Constan
Page 289 and 290:
System Op.Hours 12 33 1 96 14 196 1
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Reliability I Safety Terminology Te
Page 293 and 294:
Reliability I Safety Terminology Te
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j ""
Page 297 and 298:
Mean Time to Restore Tiempo Medio p
Page 299 and 300:
Availability. Single Failure Mode D
Page 301 and 302:
Availability. Periodic Test and Ins
Page 303 and 304:
The Effects of Incomplete Testing E
Page 305 and 306:
Safety Integrity Levels - PFH Nivel
Page 307 and 308:
Section 3: System Reliability Engin
Page 309 and 310:
Quantitative System Analysis Techni
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[ Fault Trees Arboles de Falla l AC
Page 313 and 314:
Fault Tree Model - PFavg Modele de
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Markov Models [__________ M~od~e~l~
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Multiple Failure Modes Multiples Mo
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Final Element Failure Modes Modos d
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Availability- Failure Modes Disponi
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Common Cause - Beta Model Causa Com
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exSILentia Beta Estimator exSILenti
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Common Cause - Beta Model Causa Com
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Failure Modes and Effects Analysis
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Failure Modes and Effects Analysis
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Multiple Failure Modes Multiples Mo
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Four Categories of Failure Rates Cu
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Failure Modes, Effects and Diagnost
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IEC61508/IEC61511 Safe Failure Frac
Page 341 and 342:
exida Failure Rates ex ida Ratas de
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Application Exercise Set 4 Ejercici
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Functional Safety and the Safety Li
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A FSM Plan describes the Safety Lif
Page 349 and 350:
~ Operated by the CFSE Governing Bo
Page 351 and 352:
IEC 61511 Functional Safety Assessm
Page 353 and 354:
Basic Architectures Arquitecturas B
Page 355 and 356:
2oo2 Architecture - Redundancy to r
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New Generation Architectures Arquit
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Hybrid Diagnostic Based Architectur
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~~~~~~: Hardware Architecture Fault
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IEC 61511 field equipment IEC 61511
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l Section 7: Safety Instrumented Sy
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Equipment Selection Selecci6n de Eq
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exida Recommended Prior Use Criteri
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exida Recommended Prior Use Criteri
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IEC 61508 Certified Product Pressur
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~,,_,, ,...,, ;i;l'!EC€1151!8 CER
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[ Safety Manual Manual de Seguridad
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Failure Rate Data Models Modelos de
Page 381 and 382:
[ Markov Analysis Analisis de Marko
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SIF Verification Example Ejemplo de
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SIF Verification Example Ejemplo de
Page 387 and 388:
IEC61508 Safe Failure Fraction IEC6
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Trip Setting: Alarm Setting Diagnos
Page 391 and 392:
Ex 3: Safety Transmitter+Safety PLC
Page 393 and 394:
SIL Verification Tool Verificaci6n
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SIL Verification Tool Herramienta p
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Detailed Safety Lifecycle Cicio Vid
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Terms [ Terminos ~---- (r, Factory
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Installation Activities: Environmen
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Validation Activities Validaci6n: A
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Function Safety Assessment Funci6n
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Detailed Safety Lifecycle Cicio Vid
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Proof Test Prueba '\lt-me Proof tes
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Strategic Proof Test Estrategico de
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Periodic Inspection Testing I Recor
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Section 9: Operational Requirements
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References [ ~-------------R_e_f_e_
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Revision 4.0, September 2008 Functi
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Revision 4.0, September 2008 5. Whe
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FSE II, 4.0 -Solutions to Exercises
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FSE II, 4.0 - Solutions to Exercise
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e
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0 0
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0 0
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depends on the correct functioning
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Five failure modes were obtained wh
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and Reliability.,. He is a fellow m
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0 0
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Other data sources include: 1. FMD-
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Table 1: Field ~·•~na ports I I
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Sfflnsnr Port !nforrnath:m 0 0 Figu
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0 0
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Techniques for achieving reliabilit
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