Functional Safety (IEC61508/61511) for the Process Industries - Live online course
For project managers and engineers involved with hazardous processes, this workshop focuses on the management, planning and execution of automatic safety systems in accordance with IEC 61511, the newly released international standard for process industry safety controls. (See over for background to IEC 61511).
IEC 61511 has been recognised by European safety authorities and by USA based process companies as representing the best practices available for the provision of automatic safety systems. The new standard captures many of the well established project and design techniques that have been described since 1996 in ANSI/ISA standard S84 whilst introducing many newer principles based on the master standard IEC 615108. The newly released standard IEC 61511 (published in 3 parts) combines the principles of IEC 61508 and S84 into a practical and easily understood code of practice specifically for end users in the process industries.
The workshop manual provided with this course includes all material presented in the workshop and provides details beyond the scope of two days of training. The modular format of the manual allows our presenters to adjust the subject material covered in the two day workshop to meet the needs of participants whilst the manual will serve as a reference for future studies.
WHAT YOU WILL GAIN
- Take away a checklist that you can use to quickly access if your plant complies with the latest international safety standards.
- Walk away with a solid fundamental knowledge of IEC 61511 and IEC 61508 which you can apply immediately to your plant.
- Ability to comply with the IEC 61511 and IEC 61508 standards thus signifying that your company is following the best available safety practices for a process company
- Get a practical understanding of the key sections of IEC 61511 and 61508 without wading through hundreds of pages of standards documents.
- Be able to determine required SIL ratings using at least 3 different methods as listed in IEC 61511. This has the potential to save costs by avoiding needlessly high specifications for your trip systems.
- Be able to configure safety systems to minimise or avoid spurious trips and create the potential to reduce production losses.
- Know what can be done and what should not be done with PLC’s and smart sensors.
- Know how to take advantage of smart positioners and other self testing devices to reduce down time needed for proof testing.
- Have overall knowledge of the key design and procedural requirements of IEC 61511 to ensure your safety systems comply with the best international codes of practice.
- Know how to set up function safety management procedures to meet international standards and be well prepared for independent assessments.
- The ability to plan and integrate all stages of a safety system project.
- Know how Hazop studies are performed and be able to define safety system requirements during Hazop studies.
- Know how to allocate safety tasks to both instrumented and non-instrumented protection layers to reduce dependency on a single method of protection.
- Be able to quickly estimate feasibility and costs of safety measures during Hazop studies.
- Take the mystery out of the IEC 61511 and 61508 standards.
- Demonstrate personnel competency in the latest international standard.
- Gain financial advantage for your company by eliminating high installation costs.
- Gain insight into these valuable topics from an independent, unbiased, company with a significant track record in presentation of effective training solutions.
WHO SHOULD ATTEND?
- Automation/machinery design engineers
- Control systems engineers
- Chemical or energy process engineers
- Instrument/electrical engineers and technicians
- Instrument suppliers technical staff
- Maintenance supervisors
- Project engineers and project managers
This is an intensive online course. The course is split up in to two sections – Live sessions and recorded lectures. All 8 hours will be provided upon course completion for review.
Overview of Safety Instrumented Systems for Managers
This session describes the role of safety instrumented system as part of the overall risk reduction measures that a company will typically install to deal with a hazardous process. It explains the basic technical features of a safety system and shows what tasks must be carried out to ensure that the protection measures are properly defined and implemented. The key features of safety systems are described in non-technical terms and the relevance of these features to the capital cost and operating costs are spelt out.
This session then describes the developments that have resulted in a comprehensive new internationally accepted standard, IEC61511 being available specifically for use in the process industries. The session explains the scope and importance of IEC 61511 as a means to achieve and demonstrate high quality in applied safety systems. It is important at this stage to include good coverage of the existing standard ANSI/ISA S84.01 as this one of the predecessors to IEC 61511 and is the currently recognised standard in the USA for achieving compliance with OHSA regulations as applied to SIS.
Past failures of safety systems have very often been attributed to human errors in their design and upkeep. Authorities responsible for enforcement of safety have come to the realisation that the management of all safety activities is therefore as important as the technical equipment used to carry out safety functions. This is why IEC 61511 defines the management of safety life cycle activities as one of the critical issues in achieving compliance with the standards.
This session outlines the requirements for management of safety life cycle activities that are spelled out in IEC 61511 and discusses issues such as third party audits and assessments, staff competency requirements and conformity assessment schemes.
Introduction to IEC 61511 and the Safety Lifecycle
This session presents the background to functional safety principles and then introduces IEC 615108 and IEC 61511. It explains their joint purpose and then shows the split of responsibilities between Vendors (where IEC 61508 is generally applicable) and Users (where IEC 61511 predominates). At this stage substantial coverage is given to ANSI/ISA S84.01, this being the currently accepted standard in the USA for OHSA compliance.
With this background in place the session describes the safety lifecycle phases and explains key points relevant to each phase. The specific requirements of IEC 61511 are summarised.
Hazop methods and hazard analysis for defining risk reduction requirements
This session includes a brief presentation on Hazop study methods for continuous and batch processes. It provides practical guidance on the identification of hazards and the ranking of risks according to severity and likelihood. Practical examples of risk matrix methods and documentation systems are provided.
Principles of risk reduction and safety allocation
This session describes stage 2 of the IEC 61511 safety life cycle and provides training in the principles of recognising layers of protection and the allocation of risk reduction measures to both instrumented, and non- instrumented, protection systems. It provides detailed guidance on preparation of a typical ‘safety requirements specification’ in which the individual safety functions are properly defined. Further, this session raises awareness of the key importance of Hazoping to IEC61511, but it is not training in Hazops specifically. (Please refer to our Hazops workshop for this.)
Practical SIL determination methods based on IEC 61511
This session addresses the basic question: How can we decide the SIL ratings for our safety functions? Part 3 of IEC 61511 is dedicated to this subject. Our session here provides training in each of the methods for SIL determination described in the standard.
Worked examples are presented for quantitative and qualitative SIL determination and these are followed by practical exercises to ensure participants have confidence in the methods they have studied.
Practical SIS configurations for both safety and availability targets
This session explains SIS architectures such as 1oo1 and 2oo3 and shows how the two performance objectives of safety and avoidance of spurious trips can be satisfied by the arrangement of redundant sensors, logic solvers and actuators. IEC 61511 defines constraints on the SIL ratings that can be achieved by various architectures and these principles are fully covered in this session.
Practical selection of sensors and actuators for safety duties
This session trains participants to know what to look for when selecting instruments for safety. IEC 61511 requires instruments selected for safety duties to have good fail safe characteristics and must have a proven track record of good performance in safety applications. The new standard requires special provision for smart transmitters and programmable devices in general. Many companies are not aware that the instruments they have selected will not satisfy IEC 61511 and will not pass a safety audit.
Practical reliability analysis methods and programs to IEC 61511
This session shows how to carry out simple reliability calculations to evaluate the design of a safety function in terms of its probability of failure on demand and shows how to verify that the required SIL rating has been achieved. Training is provided in 1st principles using simplified reliability formula based on IEC 61508 part 6. The session shows how calculations can be checked against reference tables in IEC 61508 and how simple spreadsheet applications can be set up. The training includes a review of SIL calculation software packages with demonstrations using one or more packages.
Practical selection of safety controllers
This session describes the essential characteristics of various types of safety-certified PLC's and explains why regular PLC’s are not acceptable for safety duties. Practical selection issues are discussed with the aid of guideline found in IEC 61511 and involving hardware and application software. This session will support participants involved in the evaluation of available safety certified PLC’s.
Practical system integration and application software for safety controllers
This session reviews key stages in the hardware and software implementation activities as defined by IEC 61511. It will assist participants to plan the engineering of hardware and in the configuration of the application programs for safety controllers
Practical documentation and validation of SIS systems.
This assists participants to plan the complete documentation package required for IEC 61511 safety life cycle stages. This includes document formats for the hazard identification stage, safety requirements specification and SIL determination stages. It will explain the principles of verification of each stage of the project and will then show how validation should be planned by preparing documents for testing and recording results.
Practical diagnostics and proof testing of safety instrumentation
This session provides training in practical methods for proof testing and then extends to show how auto-diagnostic methods can be applied to field instruments. This session links the guidelines on diagnostic methods found in IEC 61511 to some practical examples such as partial closure testing of valves. The training shows how smart positioners can be used to reduce proof testing frequencies or improve SIL ratings.