Is it a common approach for machine and process ?

Functional Safety :-
• fundamental to the enabling of complex technology used for safety-related systems.
• assurance that the safety-related systems will offer the necessary risk reduction required to achieve safety
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Functional safety is part of the overall safety that depends on a system or equipment operating correctly in response to its inputs. Functional safety is achieved when every specified safety function is carried out and the level of performance required of each safety function is met.
Functional safety relies on active systems .
Safety Instrumented
System (SIS)
Inputs Outputs
Basic Process Control
System (BPCS)
Inputs Outputs
Reactor
Safety achieved by measures that rely on passive systems is not functional safety.
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Process Industry:
People, Investments, Environment
Process Control
Reaction time 0.1 ...1s
IEC 61.511,....
ISA 84
TÜV
Hazardous substances, pressure
Heating
Manufacturing:
People and Machines
Production Cells / Centers
Reaction time 5 ...150ms
EN60204, IEC947-1,....
NFPA 79, ISO 13849,....
62061
TÜV / UL /
BG / BIA movements
Transportation
Actuators
Sensors
Fail-safe Automation
Heat
Materials
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Specifications 44.1%
Changes after startup
20.6%
Operation & maintenance
14.7%
Design & implementation
14.7%
Installation & startup
5.9%
Note : Based on 34 investigated incidents in the UK
Health and Safety Executive (GB): Out of Control. Why control systems go wrong and how to prevent failure. HSE Books 1995
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Failure causes
ƒ
ƒ
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Personnel qualifications
+
Safety management
+
Technical requirements
Analysis
Specifications
Design & implementation
Installation & startup
Operation & maintenance
Changes after startup
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Relevant good practice
IEC 61511
IEC 61508
IEC 62061 ISO 13849
EN 954
(until 2009)
Harmonized standards
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Process
Industry
Manufacturing Industry
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What makes a person competent?:
Qualifications, experience and “appropriate qualities”
ƒ Training to ensure suitable knowledge of the standards / legislation / field / sector / products (Who?).
ƒ Adequate knowledge of the hazards and failures of the equipment / process / system.
ƒ Knowledge and understanding of working practices of organisation (work / contracted).
ƒ Ability to communicate effectively with peers / staff / supervisors.
ƒ Appreciation of their own limitations and constraints
ƒ Willingness to point out own limitations.
Competence Management Systems (CMS)
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Control of dangerous failures during operation
Æ
Avoidance of systematic failure in the concept, production and operation of the systems
Æ
Technical design requirements of safety-related functions
ƒ System Architecture
ƒ Failure Probability
Requirements of planning processes and methods
ƒ Functional Safety Management
ƒ From hazard/risk analysis through to decommissioning of SRS
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Process Industry
IEC 61511
Manufacturing Industry Manufacturing Industry
IEC 62061 ISO 13849-1
Policy / Strategy
Safety Management System
Roles / Responsibilities
Roles / Competence
Risk Evaluation / Management
Safety Planning
Procedures:
ƒ Implementation / Monitoring
ƒ Functional Safety Assessment
ƒ Auditing / Revision
ƒ Configuration Management
Safety Plan to include:
Policy / Strategy
Application Software
Roles / Responsibilities
Procedures & Resources:
ƒ Hazard / Risk Assessment
ƒ Equipment
ƒ Responsible Organisation
ƒ Achieve / Maintain Func. Safety
Configuration Management
Verification Plan
Validation Plan
DOES NOT MENTION FSM
Software LIFECYCLE
Hazard / Risk – “Life Cycle”
Annex G – Systematic Failure
Measures for the control of systematic failures
Measures for the avoidance of systematic failures
Defined Validation Process:
ƒ Basic safety principles
ƒ Well-tried components
ƒ Well-tried safety principles
ƒ Defined rules for software
FSM = a good mechanism for demonstrating the implementation of:
ISO 13849-1
ISO 13849-2 (Validation)
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Verification (in general) =
“Are you making it right?"
Verification is the process used to evaluate whether or not a system complies with regulations / specifications / conditions imposed at the start of a phase.
Validation (in general) =
"Are you making the right thing?“
Validation is the process of establishing evidence (including functional testing) that provides a high degree of assurance that a system accomplishes its intended requirements (Fit for purpose).
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Document everything!
EHSR
Hazard identification
Risk assessment & risk reduction
Verification
Validation
Technical File
Technical Construction File
Competence Management System
Operating Procedures
Maintenance / Isolation Procedures
Emergency Procedures
Inspections / Metrics / Audits / Reviews
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Commitment to Safety
ƒ
Culture
ƒ
Compliance
ƒ Competence
Risk Assessment
ƒ
Knowledge management
ƒ
Hazard Identification & risk assessment
Managing Risk
ƒ
Operating procedures / Safe working practices
ƒ
Asset integrity management
ƒ Emergency management
Learning from Experience
ƒ
Accidents & near misses
ƒ
Measurement metrics, audit & review
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Extensive experience in functional safety for both Machine and Process sectors.
Currently:
ƒ Market leader in Machine Safety
ƒ Fastest growing in Process Safety
We have the products:
ƒ Largest Portfolio of Safety Products
ƒ Expertise in IEC 61508
Accident prevention must not be regarded as the rule of law, but rather as a dictate of human commitment and economic rationality
(Werner von Siemens in the year 1880)
We can deliver safety projects:
ƒ Through competent partners
ƒ In-house
We can provide safety services
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Process Industry
IEC 61511
Manufacturing Industry Manufacturing Industry
IEC 62061 ISO 13849-1
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Detecting Evaluating
ƒ
SIRIUS position switches
ƒ
SIRIUS signal columns
ƒ SIRIUS EMERGENCY STOP
ƒ SIRIUS speed monitors
ƒ ASIsafe safe modules
ƒ
SIMATIC Panel 277F IWLAN
ƒ SITRANS P
ƒ SITRANS T
ƒ SITRANS LR
ƒ OXYMAT 6 / ULTRAMAT 6
ƒ
SIRIUS safety relays
ƒ
SINAMICS ( )
ƒ SIRIUS MSS
ƒ ASIsafe
ƒ SIMATIC S7-300
ƒ
SIMATIC S7-400
ƒ SIMATIC PCS7
ƒ SIMATIC ET200
Reacting
ƒ
SIRIUS contactors
ƒ
SIRIUS motor starters
ƒ SIRIUS compact feeder
ƒ SIMOCODE
ƒ SINAMICS G120 / G120D
ƒ
SINAMICS G130 / G150
ƒ SINAMICS S110
ƒ SINAMICS S120
ƒ SINAMICS S150
ƒ SINAMICS GM150/SM150
ƒ SITRANS PS2 positioner
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ƒ Deep expertise in developing safety certified products
ƒ
Largest portfolio of IEC 61508 safety-certified products
ƒ Safety and high-availability products integrated into machine automation and process automation systems
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Process Industry
IEC 61511
Manufacturing Industry Manufacturing Industry
IEC 62061 ISO 13849-1
ƒ Management and assessment of functional safety and audits
ƒ
Safety planning
ƒ Hazard and risk assessment
(HAZID / HAZOP)
ƒ Allocations of safety functions to protection layers
ƒ
SIL assessments (risk graph,
LOPA)
ƒ Safety requirement specifications
ƒ Assessment of safety-related application code
ƒ
Verification & Validation
ƒ Modification
ƒ Training
ƒ Management and assessment of functional safety
ƒ Safety planning
ƒ
Hazard and risk assessment
(ISO 12100)
ƒ SIL assessments
ƒ Safety requirement specifications
ƒ
Assessment of safety-related application code
ƒ Verification & Validation
ƒ Modification
ƒ Training
ƒ Management and assessment of functional safety
ƒ Safety planning
ƒ Hazard and risk assessment
(ISO 12100)
ƒ PL assessments
ƒ Safety requirement specifications
ƒ Assessment of safety-related application code
ƒ
Verification & Validation
ƒ Modification
ƒ Training
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Pete Brown
Functional Safety Specialist
Customer Services
Siemens Industry
Ian Curtis
Process Safety Systems Consultant
Industry Automation
Siemens Industry
Protection notice / Copyright notice