SAFETY INSTRUMENTED SYSTEMS
Manual for Plant Engineering and Maintenance
With reference to IEC 61508 Standard for Functional Safety of Electrical / Electronic / Programmable Electronic
Safety-Related Systems and IEC 61511 Safety Instrumented Systems for the Process Industry
3rd Edition
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This manual is a practical aid for the analysis, installation and maintenance of safety instrumented systems and associated components and will hopefully serve as a guide for understanding procedures and transposing them into practice.
It represents our effort to share the results we have come to after many years of research and field experience, with anyone willing to approach Safety Related Systems.
Who this manual is for
This manual is not intended for safety reliability specialists, but for the thousands of professionals employed in process industries who work with
safety instrumented systems and who are expected to follow the appropriate industry standards.
Aren’t the standards alone enough? The answer depends upon the knowledge and experience of the individual and the company.
The growing demand for experts in a critical sector like functional safety, underlies the urgency of a greater awareness and comprehension of all subjects presented herein.
Index
Authors ................................................................................................... 3
Why this manual was written......................................................................... 4
Who this manual is for ................................................................................... 4
Index .................................................................................................... I
Chapter 1 Presentation of IEC 61508, IEC 61511 and other safety
related standards..................................................................... 1
1.1 Scope of the IEC 61508 .................................................................................... 4
1.1.1 Safety ........................................................................................................... 5
1.1.2 IEC 61508: Brief description. ....................................................................... 7
1.2 Other safety-related standards........................................................................ 10
1.2.1 HSE- PES................................................................................................... 10
1.2.2 DIN (V) 19250 ............................................................................................ 10
1.2.3 AIChE - CCPS............................................................................................ 11
1.2.4 ISA-SP84.01 - 1996 ................................................................................... 11
1.2.5 API RTP 556 .............................................................................................. 12
1.2.6 NFPA 85..................................................................................................... 12
1.2.7 IEC 61511 – 2004 (ANSI/ISA-84.00.01-2004)........................................... 12
1.2.8 API RP 14C................................................................................................ 13
1.2.9 Risk of relevant accidents, in EEC and Italian Standards ......................... 13
Chapter 2 Prevention and mitigation layers for hazardous events .... 15
2.1 Plants and processes in their environmental context .................................... 18
2.2 Process Control System.................................................................................. 20
2.3 Alarm system................................................................................................... 21
2.4 Emergency Shutdown system......................................................................... 23
2.5 Physical protection and release devices......................................................... 24
2.6 Physical protections and containment systems .............................................. 26
2.7 Physical protections and dispersion systems ................................................. 27
2.8 Physical protections and Fire & Gas neutralizing systems............................. 27
2.9 Internal emergency plan (evacuation procedures) ........................................ 29
IIndex
2.10 External emergency plan (evacuation procedures) .......................................29
Chapter 3 Basic concepts for a better comprehension of safety
standards ............................................................................... 31
3.1 Reliability and Unreliability ..............................................................................31
3.1.1 Reliability ....................................................................................................31
3.1.2 Unreliability.................................................................................................34
3.2 Availability and unavailability...........................................................................36
3.2.1 Ambiguity of the term “availability” .............................................................38
3.2.2 Achievable Availability................................................................................41
3.2.3 Operational Availability...............................................................................41
3.3 MTTF, MTTR, MTBF and their relations .........................................................42
3.4 Failure Rate.....................................................................................................45
3.4.1 Components with constant failure rate.......................................................47
3.4.2 Failure rate Categories...............................................................................48
3.4.3 Dependent, or common cause, failures .....................................................50
3.4.4 Common cause failures and Beta factor....................................................51
3.5 Safety analysis for SIL level selection: Modeling methods ............................52
3.5.1 Reliability block diagrams...........................................................................52
3.5.2 Fault tree analysis ......................................................................................54
3.5.3 Markov diagrams........................................................................................59
Chapter 4 Consequence Analysis of relevant accidents involving
chemical substances ............................................................ 71
4.1 Analysis of risks from the release of chemical substances.............................71
4.2 Flammability effects.........................................................................................76
4.2.1 Pool fire ......................................................................................................76
4.2.2 Jet fire.........................................................................................................78
4.2.3 Flash fire.....................................................................................................79
4.2.4 Fireball / BLEVE .........................................................................................80
4.2.5 Explosion effects ........................................................................................81
4.3 Toxic hazard: Dispersion modeling .................................................................84
Chapter 5 Safety Instrumented Systems (SIS)..................................... 87
5.1 Introduction......................................................................................................87
5.2 Safety requirements ........................................................................................89
5.3 Average Probability of Failure on Demand (PFDavg), Safety Integrity Levels
(SIL).................................................................................................................91
5.4 System architectures.......................................................................................98
5.4.1 Introduction.................................................................................................98
IIIndex
5.4.2 Common cause factor (β) and PFDavg for redundant architectures....... 102
5.4.3 1oo1 system architecture......................................................................... 104
5.4.4 1oo2 architecture ..................................................................................... 112
5.4.5 2oo3 system architecture......................................................................... 118
5.4.6 Comparison between system architectures............................................. 122
5.5 Summary of simplified equations .................................................................. 124
5.5.1 Influence of time interval and duration of periodic tests, on PFDavg, for
redundant equal components .................................................................. 126
5.5.2 Application exercises using simplified equations..................................... 126
5.6 Use of valves in Safety Instrumented Systems............................................. 128
5.6.1 Bypass examples and possibilities of on-line periodic proof testing for
SIS shutdown valves, or other field devices used in 1oo1 system
architecture .............................................................................................. 128
5.6.2 Partial Stroking Test (PST) for valves...................................................... 130
5.6.3 Full Stroke Test of valves (FST) .............................................................. 132
5.7 SIS Conceptual Design ................................................................................ 133
5.7.1 Conceptual Design Requirements ........................................................... 134
5.8 Lifecycles cost analysis................................................................................. 136
5.9 Conceptual Design and SIL Level................................................................. 137
Chapter 6 IEC 61508: Fundamental concepts .................................... 139
6.1 Overall safety lifecycle................................................................................... 139
6.2 Safety Integrity Levels................................................................................... 141
6.3 Part “1”: General requirements ..................................................................... 142
6.3.1 Scope ....................................................................................................... 142
6.3.2 Compliance .............................................................................................. 143
6.3.3 Documentation (Clause 5) ....................................................................... 144
6.3.4 Management of Functional Safety (Clause 6) ......................................... 145
6.3.5 Overall Safety Lifecycle Requirements (Clause 7) .................................. 146
6.3.6 HSE Findings ........................................................................................... 147
6.3.7 The concept of safety lifecycle in IEC 61508........................................... 148
6.3.8 Functional Safety Assessment (Clause 8)............................................... 151
6.3.9 Example documentation structure (Annex A) .......................................... 152
6.3.10 Competence of persons (Annex B).......................................................... 153
6.4 Part “2”: Hardware Requirements ................................................................. 154
6.4.1 Control of Failure during Operation (Annex A) ........................................ 157
6.4.2 Avoidance of Systematic Failures during different phases of the Lifecycle
(Annex B) ................................................................................................. 157
6.4.3 Diagnostic Coverage and Safe Failure Fraction (Annex C)..................... 158
IIIIndex
6.5 Part “3”: Software requirements ....................................................................159
6.5.1 Software Functional Safety Plan (Clause 6) ............................................159
6.5.2 Software Safety Lifecycles (Clause 7) .....................................................161
6.5.3 Software Safety Requirements Specification (Clause 7.2) .....................163
6.5.4 Software safety validation planning (Clause 7.3).....................................163
6.5.5 Software design and development (Clause 7.4)......................................164
6.5.6 Integration and testing (Clause 7.5).........................................................165
6.5.7 Software safety validation (Clause 7.7) ...................................................165
6.5.8 Operation and modification (Clause 7.6 and 7.8) ....................................166
6.5.9 Software verification (Clause 7.9) ............................................................167
6.5.10 Software Functional Safety Assessment (Clause 8)................................167
6.5.11 Guide to the selection of techniques and measures (Annexes “A” and
“B”)............................................................................................................168
6.6 Part “4”: Definitions and abbreviations ..........................................................169
6.7 Part “5”: Safety Integrity Level determination................................................169
6.7.1 Risk Reduction – General concepts.........................................................169
6.7.2 Risk and safety integrity: general concepts (Annex A) ...........................173
6.7.3 ALARP and tolerable risk concepts (Annex “B”)......................................174
6.7.4 Tolerable Risk decisions based on financial considerations ..................176
6.7.5 Quantitative method for SIL determination (Annex “C”)..........................179
6.7.6 Qualitative method: Risk graph (Annex “D”) ............................................182
6.7.7 Determination of the SIL level: qualitative method, Hazardous event
severity matrix (Annex “E”).......................................................................185
6.7.8 Layer of Protection Analysis (LOPA)........................................................185
6.8 Part “6”: Guidelines in the application of Parts 2 and 3................................189
6.8.1 Application of Parts 2 and 3 (Annex “A”)..................................................189
6.8.2 Example technique for evaluating probabilities of hardware failure
(Annex “B”) ...............................................................................................189
6.8.3 Diagnostic Coverage calculation and Safe Failure Fraction: Worked
example (Annex “C”) ................................................................................189
6.8.4 Methodology to quantify the effect of the common failures of the
hardware in the E/E/PE multichannel systems (Enclosure “D”)...............193
6.8.5 Applicative example of the integrity software table of Part 3 (Enclosure
“E”)............................................................................................................193
6.9 Part 7: Overview of techniques and measures .............................................194
6.9.1 Overview of techniques and measures for E/E/PES: control of random
hardware failures (Annex “A”) ..................................................................194
6.9.2 Overview of techniques and measures for E/E/PES: avoidance of
systematic failures (Annex “B”) ................................................................194
IVIndex
6.9.3 Overview of techniques and measures for achieving software safety
integrity (Annex “C”)................................................................................. 194
6.9.4 A probabilistic approach to determining software safety integrity for predeveloped software (Annex “D”) ............................................................. 194
Chapter 7 IEC 61511 Safety Instrumented Systems for process industry................................................................................. 195
7.1 Part 1: Framework, definitions, system, hardware and software
requirements ................................................................................................. 196
7.2 Part 2: Guidelines in the application of IEC 61511 ...................................... 198
7.3 Part 3: Guidelines in the application of hazard and risk analysis ................ 199
Chapter 8 Proven-in-use assessment ................................................. 201
8.1 Defining the term “proven-in-use” according IEC 61508-7 ........................... 201
8.2 “Proven-in-use” requirements according to IEC 61511-1 ............................. 202
8.3 Required information for a proven-in-use proof of a sub-system ................. 203
Chapter 9 Functional safety manual.................................................... 205
9.1 Requirements................................................................................................ 205
9.2 Example ........................................................................................................ 207
Chapter 10 SIS design checklists .......................................................... 209
10.1 Management Requirements.......................................................................... 210
10.2 Safety Requirements Specification ............................................................... 211
10.3 Conceptual SIS Design ................................................................................. 212
10.4 Detailed SIS Design ...................................................................................... 213
10.5 Power & Grounding....................................................................................... 214
10.6 Field Devices................................................................................................. 215
10.7 Operator Interface ......................................................................................... 216
10.8 Maintenance/Engineering Interface .............................................................. 217
10.9 Communications............................................................................................ 217
10.10 Hardware Specifications ............................................................................... 218
10.11 Hardware Manufacture.................................................................................. 219
10.12 SIF Components ........................................................................................... 220
10.13 Application Logic Requirements.................................................................... 222
10.14 Embedded (Vendor) Software ...................................................................... 223
10.15 Software Coding............................................................................................ 224
10.16 Factory Test .................................................................................................. 225
10.17 Installation & Commissioning........................................................................ 226
10.18 Operations & Maintenance............................................................................ 228
10.19 Testing...........................................................................................................230
10.20 Management of Changes..............................................................................231
10.21 Decommissioning ..........................................................................................232
Index of Words............................................................................................ 233
Index of Figures.......................................................................................... 236
Index of Tables ........................................................................................... 239
Reference .............................................................................................. 241
Denial of responsibility .............................................................................. 242
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