Functional Safety Demystified September 2011 Bob Weiss Principal Consultant Honeywell Process Solutions bob.weiss@honeywell.com Outline • What is Functional Safety? - SIS, SIF and SIL • Standards AS IEC61508 and AS IEC61511 • An example to demonstrate compliance • 4.5 day TÜV FSEng course in 45 minutes! 2 HONEYWELL - CONFIDENTIAL File Number What is Functional Safety? • Part of Overall Safety - freedom from unacceptable risk • Achieved by a Safety Instrumented System (SIS) - E/E/PE Safety System in IEC61508 - Examples: Emergency Shutdown System Burner Management System - Includes field devices as well as logic solver • A SIS places or maintains a process in a safe state - Process = Equipment Under Control (EUC) in IEC61508 - Implements Safety Instrumented Functions (SIFs) - Each SIF achieves a Safety Integrity Level (SIL) • Acronyms to remember: SIS, SIF and SIL !. 3 HONEYWELL - CONFIDENTIAL File Number Some terms: SIS, SIF and SIL Temperature transmitter SIF 1: TZH1234 SIL 2 Solenoid Temperature transmitter Shut-off valve SIF 2: PZHH1234 SIL 1 Pressure Transmitter Flow transmitter Logic Solver (Safety PLC) Relay in MCC Solenoid Globe valve Safety Instrumented System - SIS Safety Instrumented Function - SIF Safety Integrity Level - SIL 4 HONEYWELL - CONFIDENTIAL File Number Why Functional Safety? • Buncefield, England 11 Dec 2005 • Storage tank level gauge showed constant reading • High level alarm switch jammed • Gasoline tank overflowed • Mist exploded - Largest explosion in peacetime - 20 tanks on fire - Burned for three days - Significant environmental impact - Millions of pounds damage. 5 HONEYWELL - CONFIDENTIAL File Number Standards: IEC61508 or IEC61511 ? AS/IEC 61508 SIS Component Manufacturers AS/IEC 61511 SIS Integrators & Users OR SIL4 APPLICATIONS 61508 6 61511 61511 61508 HONEYWELL - CONFIDENTIAL 61508 61511 File Number IEC61511 Safety Lifecycle 10 9 Management of functional safety and functional safety assessment and auditing Safety life-cycle structure and planning Engineering Contractor 1 2 Hazard and risk analysis End User 7 Verification Allocation of safety functions to protection layers 3 Safety requirements specification for the safety instrumented system 4 SIS Vendor 11 Design and engineering of safety instrumented system Design and development of other means of risk reduction 5 Installation, commissioning and validation 6 Operation and maintenance 7 Modification 8 Decommissioning HONEYWELL - CONFIDENTIAL File Number Complying with AS IEC 61508 & AS IEC 61511 • Target SIL must be specified for each SIF based on hazard and risk analysis • Processes for SIS throughout lifecycle must comply • Each SIF must meet target SIL requirements for: - Architectural constraints - Random failure rate (PFDave) - Development process for each component Field devices, logic solver, shutdown valves etc. • Not just TÜV certification - Though it helps ! • Not just meeting PFDavg target. 8 HONEYWELL - CONFIDENTIAL File Number Comply Throughout Lifecycle • For the rest of the presentation we’ll follow the SIS lifecycle • What do we need to do to comply at each stage? • See the following example… - Only the main elements of compliance are covered. 9 HONEYWELL - CONFIDENTIAL File Number 1 Hazard and Risk Analysis • Output is a list of hazardous events with their process risk and acceptable risk. 10 9 Management of functional safety and functional safety assessment and auditing Safety life-cycle structure and planning 1 2 Hazard and risk analysis 11 Verification Allocation of safety functions to protection layers 3 Safety requirements specification for the safety instrumented system 4 Design and engineering of safety instrumented system 5 Design and development of other means of risk reduction Installation, commissioning and validation 6 Operation and maintenance 10 7 Modification 8 Decommissioning HONEYWELL - CONFIDENTIAL File Number Case Study: 1 A Hazard PSV-1 LIC 1 300t LPG Product Feed P-2 P-1 • “potential source of harm” • 300t of Liquefied Petroleum Gas can potentially cause harm • Hazardous Event Example: BLEVE 11 YouTube . HONEYWELL - CONFIDENTIAL File Number Case Study: 2 HazOp PSV-1 H LIC 1 300t LPG Product Feed P-2 P-1 • Node: LPG Tank • Guideword: HIGH LEVEL • Consequence: High Pressure, possible tank rupture & major fire • Existing Controls: Pressure Relief Valve (PSV-1) • New Controls: Add High Level Alarm. 12 HONEYWELL - CONFIDENTIAL File Number 2 Allocation of Safety Functions • Often called SIL Analysis or SIL Determination • Output is a list of Safety Instrumented Functions together with their required Safety Integrity Level. 10 9 Management of functional safety and functional safety assessment and auditing Safety life-cycle structure and planning 1 2 Hazard and risk analysis 11 Verification Allocation of safety functions to protection layers 3 Safety requirements specification for the safety instrumented system 4 Design and engineering of safety instrumented system Design and development of other means of risk reduction 5 Installation, commissioning and validation 6 Operation and maintenance 13 7 Modification 8 Decommissioning HONEYWELL - CONFIDENTIAL File Number Case Study: 3 Design after HazOp PSV-1 H LIC 1 300t LPG Product Feed P-2 P-1 • Is Risk acceptable? 14 HONEYWELL - CONFIDENTIAL File Number Risk The product of severity and likelihood Consequence severity Major Medium Minor LOW 15 MEDIUM HONEYWELL - CONFIDENTIAL HIGH Likelihood of occurrence File Number Case Study: 4a Risk Reduction Hazard - 300t of LPG Process under control Level stable Control valve sticks Process deviation or disturbance LAH Alarm Process out of control Hazardous situation Level Increasing High Pressure PSV Hazardous event Vessel fails Impact / Consequence 300t of boiling LPG released likely major fire and fatalities 16 HONEYWELL - CONFIDENTIAL File Number Risk Analysis - Layers of Protection 1 Mechanical PSV X 100 Target: 1 per 10,000y Hazardous Event !! Alarm LAH Risk Reduction X1 ! Control System (BPCS) Hazardous Situation : 1 per y Required: X 10,000 Only have x 100 !! Process 17 HONEYWELL - CONFIDENTIAL File Number Case Study: 4b Risk Reduction Hazard - 300t of LPG Process under control Level stable Control valve sticks Process deviation or disturbance LAH Alarm Process out of control Level Increasing LZHH Trip Hazardous situation High Pressure PSV Hazardous event Vessel fails Impact / Consequence 300t of boiling LPG released likely major fire and fatalities 18 HONEYWELL - CONFIDENTIAL File Number Case Study: 5 Add a SIF LZHH 2 LZT 2 PSV-1 H LIC 1 300t LPG Product Feed P-2 P-1 • High Level Trip LZHH2 added - Shuts off flow when High High level reached. 19 HONEYWELL - CONFIDENTIAL File Number SIL Determination 1 - Layers of Protection Mechanical PSV X 100 SIL 2 SIF LZHH X 100 Alarm LAH Control System (BPCS) Hazardous Situation : 1 per y Process 20 HONEYWELL - CONFIDENTIAL Target: 1 per 10,000y Hazardous Event !! Risk Reduction Required: X 10,000 SIF must reduce risk by 10,000/100 = 100 File Number Safety Integrity Level vs. Risk Reduction SIL Risk Reduction Factor Probability of Failure on Demand (PFDavg) Safety Availability 4 > 10,000 ≥ 10-5 < 10-4 > 99.99% 3 1,000 - 10,000 ≥ 10-4 < 10-3 99.9 - 99.99% 2 100 - 1,000 ≥ 10-3 < 10-2 99 - 99.9% 1 10 - 100 ≥ 10-2 < 10-1 90 - 99% - (Control ≤ 10) = 1 / RRF = 1 - PFDavg Used later for verifying SIL achieved 21 HONEYWELL - CONFIDENTIAL File Number SIL is more than just PFD • Target SIL must be specified for each SIF based on hazard and risk analysis • Processes for SIS throughout lifecycle must comply • Each SIF must meet target SIL requirements for: - Architectural constraints - Random failure rate (PFDave) - Development process for each component. 22 HONEYWELL - CONFIDENTIAL File Number 3 Safety Requirements Specification - SRS • Defines functional and integrity requirements of SIS • Output is set of documents ready for detail design. 10 9 Management of functional safety and functional safety assessment and auditing Safety life-cycle structure and planning 1 2 Hazard and risk analysis 11 Verification Allocation of safety functions to protection layers 3 Safety requirements specification for the safety instrumented system 4 Design and engineering of safety instrumented system Design and development of other means of risk reduction 5 Installation, commissioning and validation 6 Operation and maintenance 23 7 Modification 8 Decommissioning HONEYWELL - CONFIDENTIAL File Number Cause-and-Effect Diagram • SIFs commonly documented by Cause and Effect diagrams LZHH-02 LPG Tank High High Level 24 3200 mm HONEYWELL - CONFIDENTIAL 2 X X X X X X Set LIC1 to MAN, OP=0 0-3500 OPENS VALVE UV-03C 2 CLOSE VALVE UV-03B ~ 7 CLOSE VALVE UV-03A ~ ~ CLOSE VALVE LZV-02 1 Units Trip Point Description Burner Loss of Flame Fuel Gas Pressure Low SIL Tag# BS-01 PSL-01 Instrument Range • Could include required SIL. 0 File Number 4 Design and Engineering • SIS vendor for logic solver • EPC contractor or end-user for field hardware. 10 9 Management of functional safety and functional safety assessment and auditing Safety life-cycle structure and planning 1 2 Hazard and risk analysis 11 Verification Allocation of safety functions to protection layers 3 Safety requirements specification for the safety instrumented system 4 Design and engineering of safety instrumented system Design and development of other means of risk reduction 5 Installation, commissioning and validation 6 Operation and maintenance 25 7 Modification 8 Decommissioning HONEYWELL - CONFIDENTIAL File Number Standards Compliance • Target SIL must be specified for each SIF based on hazard and risk analysis • Processes for SIS throughout lifecycle must comply • Each SIF must meet target SIL requirements for: - Architectural constraints - Random failure rate (PFDave) - Development process for each component. 26 HONEYWELL - CONFIDENTIAL File Number FS Management System - TÜV Certification Planning SIS Order Received Customer Specifications H/W checklist S/W checklist Document Templates Execution Plan V & V Plan Design Plans Imperium Proj. P2 Plan Project Hardware Design SRS H/W Checklist TIR’s Completed H/W & S/W checklists P1 Review Customer Specifications H2 Order Hardware (preliminary) SRS (Approved) Sys H/W Spec Factory Drgs SRS FL Spec Template S/W checklist H/W checklist H3 Verify Sys H/W Spec & Fact’y Dwgs Safety Manual Function Block Library S2 Configure & Test Function Blocks PFD Calcs Sys H/W Spec (Approved) Firm Hardware Order SRS (Approved) S3 Finalise Functional Logic Spec S4 Verify Functional Logic Spec S/W checklist H/W checklist Int. Acceptance Test Report Assembled Hardware H4 Build, Deliver & Test Hardware (factory) S1 Design Software Hardware Order on Factory Hardware Implementation Certified Design & Build. Procedures • See HPS TÜV Certificate Software Design System Hardware Specification H1 Design Hardware Verified Func Blocks Func block test sheets FL Spec (Approved) Completed FL Rev Checklist Software Implementation Failsafe Control Integration Guidelines FAT Procedure (Power-up section) H5 Integrate Factory Hardware & Marshalling FL Spec SRS (Approved) Completed FAT Power-up Checklist H6 Hardware PreFAT Code Walkthrough Checklist H/W Ready for Integration S5 Configure Software on Devel’t System S6 Code Walkthrough S/W Ready for Integration Integration FAT Procedure (Pre-FAT) N1 Integration & Pre-FAT FAT Procedure System H/W Spec FL Spec, SRS N2 Factory Acceptance Test FAT) Installation Drawings N3 Install Logic Solver On Site N4 Logic Solver Site Accept. Test (SAT) SAT Procedure N5 Install, Connect & Test Field Equip. & Control System (by others) Completed FAT Proc Checklists (FAT Report) Completed SAT Proc Checklists (SAT Report) Completed System Ready for Safety Validation Configured Software Code Walkthrough Report • Covers compliance to IEC 61508 & IEC 61511 • Periodic audits and renewal • Need comparable processes for other phases. As Builts N6 Safety Validation & Commissioning (Led by Customer, with Honeywell input) 27 HONEYWELL - CONFIDENTIAL File Number Standards Compliance • Target SIL must be specified for each SIF based on hazard and risk analysis • Processes for SIS throughout lifecycle must comply • Each SIF must meet target SIL requirements for: - Architectural constraints - Random failure rate (PFDave) - Development process for each component. 28 HONEYWELL - CONFIDENTIAL File Number Case Study: 6 PFD Calculation LZHH 2 SIL 2 LZT 2 PSV-1 H LIC 1 300t LPG Product Feed P-2 P-1 • What is calculated PFDave for SIF LZHH2?. 29 HONEYWELL - CONFIDENTIAL File Number Safety Integrity Level vs. PFDave Probability of Failure on Demand (PFDavg) Safety Availability SIL Risk Reduction Factor 4 >10,000 ≥ 10-5 < 10-4 > 99.99% 3 1,000 - 10,000 ≥ 10-4 < 10-3 99.9 - 99.99% 2 100 - 1,000 ≥ 10-3 < 10-2 99 - 99.9% 1 10 - 100 ≥ 10-2 < 10-1 90 - 99% - (Control < 10) = 1 / RRF = 1 - PFDavg Implementation Focus 30 HONEYWELL - CONFIDENTIAL File Number Approximation to PFDave 1 Probability item has failed PFD(t) ~ ~ PFD average time t 0 TI = test interval PFD average = lDU TI / 2 Remember this! where lDU = Dangerous Undetected failure rate 31 HONEYWELL - CONFIDENTIAL File Number Case Study: 6 PFD Calculation • Test interval = 1 y LZV 2 • Reliability data: - Valve: - Logic solver: - Sensor: λDU = 1/10y (= 0.1 y-1) λDU = 1/1000y (= 0.001 y-1) λDU = 1/100y (= 0.01 y-1) LZHH 2 LZT 2 • PFDave = λDU x TI / 2 = 0.1 x 1 / 2 = 0.05 for valve 0.001 x 1 / 2 = 0.0005 for logic solver 0.01 x 1 / 2 = 0.005 for transmitter Total PFDave = 0.05 + 0.0005 + 0.005 = 0.0555 • Calculated SIL = 1 (PFDave range 0.01 – 0.1) • Required SIL = 2 Not OK! • How can this be fixed? 32 HONEYWELL - CONFIDENTIAL File Number Effect of Test Interval on PFDave 1 Probability item has failed PFD(t) ~ ~ Average PFD 0 TI (Test Interval) 1 PFD(t) ~ ~ Average PFD 0 TI TI TI TI time t 33 HONEYWELL - CONFIDENTIAL File Number Case Study: 7a Adjust Test Interval • Test interval = 1 month LZV 2 • Reliability data: - Valve: - Logic solver: - Sensor: λDU = 1/10y (= 0.1 y-1) λDU = 1/1000y (= 0.001 y-1) λDU = 1/100y (= 0.01 y-1) LZHH 2 LZT 2 • PFDave = λDU x TI / 2 = 0.1 / 12 / 2 = 0.004 for valve 0.001 / 12 / 2 = 0.00004 for logic solver 0.01 / 12 / 2 = 0.0004 for transmitter Total PFDave = 0.004 + 0.00004 + 0.0004 = 0.00444 • Calculated SIL = 2 (PFDave range 0.001 – 0.01) • Required SIL = 2 OK • BUT operations object to monthly testing !. 34 HONEYWELL - CONFIDENTIAL File Number Case Study: 7b Duplicate Block Valves • Test interval = 1 year LZV 2A LZV 2B • Reliability data: - Valve: - Logic solver: - Sensor: λDU = 1/10y (= 0.1 y-1) λDU = 1/1000y (= 0.001 y-1) λDU = 1/100y (= 0.01 y-1) LZHH 2 LZT 2 • For 2 valves 1oo2 voting: PFDave = (0.1 x 1 / 2)2 = 0.0025 • PFDave = 0.0025 + 0.0005 + 0.005 = 0.0080 • Calculated SIL = 2 (PFDave range 0.001 – 0.01) • Required SIL = 2 OK . 35 HONEYWELL - CONFIDENTIAL File Number Standards Compliance • Target SIL must be specified for each SIF based on hazard and risk analysis • Processes for SIS throughout lifecycle must comply • Each SIF must meet target SIL requirements for: - Architectural constraints - Random failure rate (PFDave) - Development process for each component. Is one transmitter enough or do we need two? 36 HONEYWELL - CONFIDENTIAL File Number Architectural Constraints • Aim is to avoid unrealistic reliability claims - From single devices (“elements”) • Constrains SIF architecture based on: - Safe Failure Fraction - Complexity of device (“Type A” or “Type B”) - Target SIL • Outcome is required Hardware Fault Tolerance - No. of voted devices minus 1 (typically) • Use Tables in IEC61508 part 2 - IEC61511 has simplified requirements. 37 HONEYWELL - CONFIDENTIAL File Number Safe Failure Fraction • Safety valve, normally open & normally energized • In case of an out of control process, the valve has to close Undetected SAFE Closes spontaneously due to loss of energy DANGEROUS Stuck at open 38 HONEYWELL - CONFIDENTIAL SAFE Detected by voltage control Detected by diagnostics Undetected File Number Architectural Constraints – IEC61508.2 Table 2: Type A subsystems – e.g. pressure switch Safe failure fraction Hardware fault tolerance < 60 % 60 % - 90 % 90 % - 99 % ≥ 99 % Table 3: 0 SIL1 SIL2 SIL3 SIL3 1 SIL2 SIL3 SIL4 SIL4 2 SIL3 SIL4 SIL4 SIL4 Type B subsystems – e.g. Logic Solver, Smart Tx Safe failure fraction Hardware fault tolerance 0 < 60 % Not allowed 60 % - 90 % SIL1 SIL2 SIL3 90 % - 99 % ≥ 99 % 1 SIL1 SIL2 SIL3 SIL4 2 SIL2 SIL3 SIL4 SIL4 Independent Channels Required = Hardware Fault Tolerance + 1 39 HONEYWELL - CONFIDENTIAL File Number Case Study: 8 Architectural Constraints LZHH 2 LZT 2 PSV-1 H LIC 1 300t LPG Product Feed P-2 P-1 • Transmitter LZT 2 is a smart radar gauge • Can we use single transmitter to satisfy SIL 2? • Must also check for logic solver and valve. 40 HONEYWELL - CONFIDENTIAL File Number Case Study: 8 Architectural Constraints • Smart Transmitter = Type B device - Use Table 3 in IEC61508.2 • Safe Failure Fraction = 91.8% - From TÜV Certificate • For SIL 2, required Hardware Fault Tolerance = 0 • Therefore one transmitter is ok for SIL 2. Table 3: Type B subsystems – e.g. Logic Solver, Smart Tx Safe failure fraction Hardware fault tolerance 0 Std Tx LTZ 2 < 60 % Not allowed 60 % - 90 % SIL1 SIL2 SIL3 90 % - 99 % ≥ 99 % 41 HONEYWELL - CONFIDENTIAL 1 SIL1 SIL2 SIL3 SIL4 2 SIL2 SIL3 SIL4 SIL4 File Number Architectural Constraints for Logic Solver • E.g. Honeywell FSC and Safety Manager logic solvers • 1oo2D architecture OR 2oo4D architecture • All have 99% safe failure fraction - Hence all are “SIL 3 capable” • 2oo4D has lower spurious trip rate, but costs more. Table 3: Type B subsystems – e.g. Logic Solver, Smart Tx Safe failure fraction Hardware fault tolerance 0 < 60 % Not allowed 60 % - 90 % SIL1 SIL2 SIL3 90 % - 99 % FSC, SM 42 ≥ 99 % HONEYWELL - CONFIDENTIAL 1 SIL1 SIL2 SIL3 SIL4 2 SIL2 SIL3 SIL4 SIL4 File Number Standards Compliance • Target SIL must be specified for each SIF based on hazard and risk analysis • Processes for SIS throughout lifecycle must comply • Each SIF must meet target SIL requirements for: - Architectural constraints - Random failure rate (PFDave) - Development process for each component How likely is it that each component is free from systematic faults (“bugs”) ? 43 HONEYWELL - CONFIDENTIAL File Number Case Study: 9 – Transmitter Selection • Must control systematic faults • Transmitter selected must comply with IEC61508 and IEC61511 • Must either be: - Proven in use: Comparable application Sample size sufficient for 70% confidence level All failures documented or - Designed and manufactured in accordance with IEC 61508 Confirmed by independent certificate (e.g. by TÜV) “SIL x Capable”. 44 HONEYWELL - CONFIDENTIAL File Number Case Study: 9 - Transmitter TÜV Certificate 45 HONEYWELL - CONFIDENTIAL File Number Case Study: 9 - Transmitter TÜV Certification Mark 46 HONEYWELL - CONFIDENTIAL File Number Standards Compliance • Target SIL must be specified for each SIF based on hazard and risk analysis • Processes for SIS throughout lifecycle must comply • Each SIF must meet target SIL requirements for: - Architectural constraints - Random failure rate (PFDave) - Development process for each component • Design now complies. 47 HONEYWELL - CONFIDENTIAL File Number 5 Installation, Commissioning, Validation • Logic Solver installed with field equipment • Includes loop checking, validation and final functional safety assessment. 10 9 Management of functional safety and functional safety assessment and auditing Safety life-cycle structure and planning 1 2 Hazard and risk analysis 11 Verification Allocation of safety functions to protection layers 3 Safety requirements specification for the safety instrumented system 4 Design and engineering of safety instrumented system Design and development of other means of risk reduction 5 Installation, commissioning and validation 6 Operation and maintenance 48 7 Modification 8 Decommissioning HONEYWELL - CONFIDENTIAL File Number Standards Compliance • Target SIL must be specified for each SIF based on hazard and risk analysis • Processes for SIS throughout lifecycle must comply • Each SIF must meet target SIL requirements for: - Architectural constraints - Random failure rate (PFDave) - Development process for each component • Verification, Validation, Functional Safety Assessment. 49 HONEYWELL - CONFIDENTIAL File Number Case Study: 10 Verification and Validation • Verification and Validation Plan for project V&V Plan Template SIL 2 independence required (i.e. independent engineer) Define responsibilities • Verify Safety Requirements Specification • Verify hardware design documents • Verify functional specifications etc • Implement code walkthrough • Logic Solver Factory Acceptance Test - Complete integration test of application software on target hardware • Logic Solver Site Acceptance Test - Power up test on site • Safety Function Testing • Functional Safety Assessment. 50 HONEYWELL - CONFIDENTIAL File Number 6 Operations, Maintenance and Modification • The Cinderella Phases ! • User must follow a Functional Safety Management System for the life of the SIS. 10 9 Management of functional safety and functional safety assessment and auditing Safety life-cycle structure and planning 1 2 Hazard and risk analysis 11 Verification Allocation of safety functions to protection layers 3 Safety requirements specification for the safety instrumented system 4 Design and engineering of safety instrumented system Design and development of other means of risk reduction 5 Installation, commissioning and validation 6 Operation and maintenance 51 7 Modification 8 Decommissioning HONEYWELL - CONFIDENTIAL File Number Ops and Maintenance Obligations • Proof test each SIF at specified interval • Monitor design assumptions - Demand rates - Component reliability • Adjust test interval to suit • Control modifications • Ensure Maintenance and Operational Overrides are used as designed • Monitor and promptly follow-up diagnostics. 52 HONEYWELL - CONFIDENTIAL File Number Case Study: 9 Operation and Maintenance • Risk analysis assumed: Mechanical: PSV Target: 1 per 10,000y X 100 Hazardous Event !! SIF: LZHH SIL 2 X 100 Risk Reduction Alarm LAH Required:X 10,000 Control System (BPCS) Hazardous Situation - Demand on SIS once per year - What happens in practice? • SIL verification assumed: - Transmitter failure rate 0.01 y-1 - What happens in practice? • Etc etc . . . 1 per y Process • Must verify actual performance against assumptions and adjust testing as required LZHH 2 LZT 2 • Documentation of assumptions is critical. PSV-1 H LIC 1 300t LPG Product Feed P-1 53 P-2 HONEYWELL - CONFIDENTIAL File Number Case Study: 12 - Modification • LZHH logic needs modification after commissioning • Validation needed depends on highest SIL in that SIS ! TECHNIQUE / MEASURE Ref SIL 1 SIL 2 SIL 3 SIL 4 1 Impact Analysis B.35 HR HR HR HR 2 Re-verify Changed Module B.35 HR HR HR HR 3 Re-verify Affected Modules B.35 R HR HR HR 4 Revalidate Complete System B.35 --- R HR HR 5 Software Configuration Management B.56 HR HR HR HR 6 Data Recording and Analysis B.13 HR HR HR HR During early design consider splitting SIL 2 and SIL 3 systems. 54 HONEYWELL - CONFIDENTIAL File Number Summary 1 – The SIS Lifecycle 10 9 Management of functional safety and functional safety assessment and auditing Safety life-cycle structure and planning Engineering Contractor 1 2 Hazard and risk analysis End User 55 Verification Allocation of safety functions to protection layers 3 Safety requirements specification for the safety instrumented system 4 SIS Vendor 11 Design and engineering of safety instrumented system Design and development of other means of risk reduction 5 Installation, commissioning and validation 6 Operation and maintenance 7 Modification 8 Decommissioning HONEYWELL - CONFIDENTIAL File Number Summary 2 – Requirements • Target SIL must be specified for each SIF based on hazard and risk analysis • Processes for SIS throughout lifecycle must comply • Each SIF must meet target SIL requirements for: - Architectural constraints - Random failure rate (PFDave) - Development process for each component • Not just TÜV certification - Though it helps ! • Not just meeting PFDavg target • Don’t forget spurious trip rate! . 56 HONEYWELL - CONFIDENTIAL File Number Thank You... Questions? 58 HONEYWELL - CONFIDENTIAL File Number