CFSE Exam Preparation: Section I-1

Section I-1: Safety Lifecycle

 IEC61508 Objectives and Key Messages

 IEC61508 Terms
 IEC61508 - IEC61511 - CD62061
 IEC61508 Safety Lifecycle
 ISA84.01 Safety Lifecycle
 Detail Safety Lifecycle
 CFSE Exam Preparation: Section I-1

IEC 61508 - Objectives

HSE study of accident causes

involving control systems:
Specification 44%

Changes after Design &

Commissioning Implementation
21% 15%

Operation & Installation & Commissioning

Maintenance 6%
15%
CFSE Exam Preparation: Section I-1

IEC 61508 - Objectives

Safety
Accident
Causes
Management IEC61508
Technical
Requirements
Safety Life
Cycle
Competence
of Persons

Certification
 CFSE Exam Preparation: Section I-1

Safety Lifecycle Approach

Identify
The safety lifecycle
approach, as
described in ISA
Verify Assess 84.01, IEC 61511,
and IEC 61508 is a
closed loop process.

Design
4
CFSE Exam Preparation: Section I-1

Terms
E/E/PE: Electrical / Electronic /
Programmable Electronic
PES: Programmable Electronic System
SRS: Safety Related System
RR: Risk Reduction (Facility)
EUC: Equipment Under Control
SF: Safety Function
SIL: Safety Integrity Level
FSM: Management of Functional Safety
SLC: Safety LifeCycle
CFSE Exam Preparation: Section I-1

Terms
Equipment under Control
The equipment, machinery, apparatus, or plant used
for manufacturing, process, transport, medical, or
other activities. The EUC control system is separate
and distinct from the EUC.
Safety Requirements Specification
Contains:
1. The Safety Functions that have to be carried out
by the safety related systems, and
2. The Safety Integrity Levels for the various Safety
functions.
CFSE Exam Preparation: Section I-1

Terms
Random Failures
A failure occurring at a random time, which results
from one or more of the possible degradation
mechanisms.
Systematic Failures
A failure related in a deterministic way to a certain
cause, which can only be eliminated by a modification
of the design or of the manufacturing process,
operational procedures, documentation,
or other relevant factors.
CFSE Exam Preparation: Section I-1

IEC 61508 – dIEC 61511 – CD 62061

IEC 61508 Design
IEC 61511 SIL Operation
ISA S84 Maintenance
DIN V VDE 0801
EN 954-1
Communications

E/E/PES
Sensors Hardware &
Embedded Software Final
Elements
CFSE Exam Preparation: Section I-1

Terms
 Safety Instrumented Function (SIF)
 What to measure (sense)
 What to do (actuate)
 When to do (event logic)
 How fast from measure to react (timing)
Loop 1

Logic
Solver
Loop 2

Loop 3
CFSE Exam Preparation: Section I-1

Terms
 Safety Function - Example
 Restrict fuel intake to reduce high speed
 Supply coolant to reduce extreme temperature
 Open value to relief excessive pressure
 Direct 5 tons of escaping liquid to the waste
handling
 Issue fire alarm and unlock fire water pumps
 Dispatch emergency response team within
3 minutes
 CFSE Exam Preparation: Section I-1

Safety Life Cycle - IEC61508

1 Concept
“ANALYSIS”
Overall Scope
Phase 2
Definition

(End User / Consultant) 3

Hazard & Risk
Analysis

Overall Safety
4
Requirements

Safety Requirements
5
Allocation

Overall Planning Safety-related Safety-related External Risk

systems : systems : other Reduction
Operation & Installation & 9 E/E/PES 10 Technology 11 Facilities
Validation
6 Maintenance 7 8 Commissioning
Planning
Planning Planning Realisation Realisation Realisation
“REALISATION”
Overall Installation
12
& Commissioning (Vendor / Contractor /
End User)
Overall Safety
13
Validation

Overall Operation & Overall Modification

14
Maintenance
15
& Retrofit “OPERATION”
16 Decommissioning
(End User / Contractor)
CFSE Exam Preparation: Section I-1
Safety Life Cycle - ANSI/ISA S84.01
Conceptual Develop Safety Establish
Process Design Specification Operating and
Maintenance
Procedures
Hazard Analysis/ SIS Conceptual Pre-startup
Risk Assessment Design Safety Review
(Assessment)

Develop non- SIS Detailed SIS startup, Not Covered

SIS Layers Design operation,
by S84.01

maintenance, Covered by
S84.01
SIS Installation, Periodic
No SIS Functional Tests
Commissioning
Required?
and Pre-startup
Yes Acceptance Test Modify, SIS
Define Target Decommission? Decommissioning
SIL Decommission
Modify
ANALYSIS REALISATION OPERATION
CFSE Exam Preparation: Section I-1

IEC 61511 Safety Life Cycle

Risk Analysis and Protection Layer Design
Management of Safety Sub-clause 8 Verification
Functional Lifecycle
Safety and Structure
Allocation of Safety Functions to Safety Instrumented
Functional and
Systems or Other Means of Risk Reduction
Safety Planning
Sub-clause 9
Assessment

Safety Requirements Specification for

the Safety Instrumented System ANALYSIS
Sub-clause 10

Design and Development of Design and Development of Other

Safety Instrumented System Means of Risk Reduction
Sub-clause 11 Sub-clause 9

Installation, Commissioning, and Validation

Sub-clause 14 REALIZATION

Sub-
Operation and Maintenance
Sub-clause 15 OPERATION Sub-
clause
clause
Clause 5 Decommissioning 7, 12.7
6.2 Modification
Sub-clause 15.4 Sub-clause 16

13
CFSE Exam Preparation: Section I-1

Safety Lifecycle “Study” Phase

1 Concept

“ANALYSIS” 2
Overall Scope
Definition

Phase 3
Hazard & Risk
Analysis
(End User/Contractor/
Overall Safety
Consultant) 4
Requirements

Safety Requirements
5
Allocation

 Concept and scope

 Hazards and Operability (HAZOP) study
 Layers of Protection Analysis (LOPA)
 Fault-Tree analysis, Process Failure Modes and Effects Analysis
 Definition of safety functions (Cause and Effect charts)
 Safety Integrity Level (SIL) “Targets”
 CFSE Exam Preparation: Section I-1

Safety Lifecycle “Study” Phase

“REALISATION” Phase (Vendor / Contractor / End User)

Overall Planning Safety-related Safety -related External Risk

systems : systems : other Reduction
Operation & Installation & 9 E/E/PES 10 Technology 11 Facilities
Validation
6 Maintenance 7 8 Commissioning
Planning Realisation Realisation
Planning Planning Realisation

Overall Installation
12
& Commissioning

Overall Safety
13
Validation
 Architectural / Detail Design
 SIL Verification - Fault Trees / Markov Models
 Operation and Maintenance Planning
 Validation Test Planning
 Installation and Commissioning
 Validation Testing
CFSE Exam Preparation: Section I-1

Safety Lifecycle “Operation” Phase

Overall Operation & Overall Modification “OPERATION”

14 15
Maintenance & Retrofit (End User / Contractor)

16 Decommissioning

 Operation
 Risk-based Maintenance
 Periodic Inspection and Testing
 Modification Process and Retrofit
 Decommissioning
CFSE Exam Preparation: Section I-1

IEC 61508 Parts versus Phases

PART 1
PART 5
Development of the overall safety
requirements Risk based approaches to the development
(scope, hazard and risk analysis) of the safety integrity requirements

PART 2 PART 3
PART 6
Realisation phase for Realisation phase for
E/E/PE safety-related safety-related
systems software Guidelines for the
application of part 2 and 3 PART 7
PART 1 Overview of techniques
and measures
Installation and commissioning and safety validation of
E/E/PE safety-related systems

PART 1
Operation and maintenance, modification and retrofit,
decommissioning or disposal of Technical
E/E/PE safety-related systems
requirements
CFSE Exam Preparation: Section I-1 e
Safety Lifecycle
excellence in dependable automation
ida .com
Conceptual
Process Design Process Information

Event History
Identify
Potential Risks Potential Hazards
e ida.com
Layers of Protection excellence in dependable automation
PROBE Tool

Failure Probabilities Layer of Protection

Assess Potential Analysis
Risk Likelihood Hazard Frequencies

Detail
e ida.com
FETCH Tool
Analyze Potential excellence in dependable automation

Hazard Risk Magnitude Consequence

Characteristics Analysis
Hazard Consequences
Consequence

Safety
Database
Tolerable Risk Select Target Target SILs
Guidelines Develop non- SIL
SIS Layers e ida.com
excellence in dependable automation
DOCUMENT Template

Safety Requirements Specification-

Lifecycle
No
SIS Functional Description of each Safety

Requirements
Required? Exit

Allocation
Instrumented Function, Target SIL,

Safety
Yes Mitigated Hazards, Process parameters,
Logic, Bypass/Maintenance
Develop Safety requirements, Response time, etc
Specification
Select Relays, Fail-Safe Solid State, PLC, Safety
Technology PLC, Sensors, Final Elements

Select Redundancy: 1oo1,1oo2, 2003, 1oo2D

SIS Conceptual Architecture
Manufacturer’s Design
Failure Data Determine Test
Philosophy
Failure Data
Database SILVER Tool
No SIL
Achieved? Reliability, Safety SILs Achieved
Yes Evaluation
Manufacturer’s DOCUMENT Template
Safety Manual
SIS Detailed
Design Detailed Design Documentation -
Loop Diagrams, Wiring Diagrams, Logic
Diagrams, Panel Layout, PLC
Manufacturer’s SIS Installation, Programming, Installation
Installation
Installation Commissioning Requirements, Commissioning
Instructions & Commission
and Pre-startup Requirements, etc.
Planning
Acceptance Test
Verify all documentation against Hazards, design, installation
Validation: testing, maintenance procedures, management of change,
Validation Pre-startup emergency plans, etc.
exida .com , L.L.C.
Planning Safety Review
Munchen , Germany
SIS startup, +49 -89-4900 0547
Operating and operation, Sellersville, PA, U.S.A
Maintenance maintenance,
Periodic +215 -453 -1720
Planning
Functional Tests Columbus, Ohio U.S.A.
Decommission
+614 -226 -4263

18 Modify Modify,
Decommission?
SIS
Decommissioning
Port Chambers, New
Zealand
Sarnia , Canada
CFSE Exam Preparation: Section I-1

Hazard / Risk Analysis

• Objective
– Identify process hazards, estimate their
Risk analysis
and
risks and decide if that risk is tolerable
protection • Tasks
layer design
– Hazard Identification (eg, HAZOP)
Subclause 8 – Analysis of Likelihood and
Consequence
– Consideration of non-SIS Layers of
Protection

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CFSE Exam Preparation: Section I-1

SIL Selection
• Objective
– Specify the required risk reduction, or
Allocation of difference between existing and tolerable
Safety Functions risk levels – in terms of SIL
to Safety • Tasks
Instrumented
– Compare process risk against tolerable
Systems or Other
risk
Means of Risk
Reduction – Use decision guidelines to select required
risk reduction
Subclause 9 – Document selection process

20
CFSE Exam Preparation: Section I-1

Safety Requirements
Specification
• Objective
– Specify all requirements of SIS
Safety
Requirements
needed for detailed engineering and
Specification for process safety information purposes
the Safety • Tasks
Instrumented
System – Identify and describe safety functions
– Document SIL
Subclause 10
– Document action taken – Logic,
Cause and Effect Diagram, etc.

21
CFSE Exam Preparation: Section I-1

Conceptual /
Detailed Design
• Objective
– Select and configure equipment
Design and used in the SIS (including
Engineering of programming)
Safety
Instrumented • Tasks
System – Specify system technology and
architecture
Subclauses 11,
– Specify field instrumentation
12
– Configuration / Programming
– Select vendors, review bids
22
CFSE Exam Preparation: Section I-1

Installation and Commissioning

• Objective
– Install equipment, after acceptance
Installation,
Commissioning
testing, and prepare for operation
• Tasks
Subclauses 13
and 14 – Factory Acceptance Testing Field
and control room equipment
installation
– Confirm equipment operation
– Instrumentation Calibration

23
CFSE Exam Preparation: Section I-1

Safety Review
Validation
• Objectives
– Verify that the SIS is designed,
Validation installed, and operating according the
the Safety Requirements
Subclauses 13 • Tasks
– Verify operation of field instruments
– Validate logic and operation
– Verify SIL of installed equipment
– Produce OSHA and EPA required
documentation – Certifications if req.
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CFSE Exam Preparation: Section I-1

Operation and
Maintenance
• Objective
– Operate and maintain the SIS so that
Operation and the specified SIL is maintained
Maintenance • Tasks
Subclause 15 – Establish procedures for operating
and maintaining the SIS
– Perform periodic function test on an
interval that allows the specified SIL
to be achieved with the installed
equipment

25
CFSE Exam Preparation: Section I-1

Modification and
Decommissioning
• Objective
– Ensure changes to the system are
Modification and safe and appropriately reviewed
Decommissioning
• Tasks
Subclauses 15.4 – Establish procedures for change
and 16
management
– Review safety functions prior to
taking an SIS out of service

26
CFSE Exam Preparation: Section I-1

Section I-1: Safety Lifecycle Review

 IEC61508 Objectives and Key Messages

 IEC61508 Terms
 IEC61508 - IEC61511 - CD62061
 IEC61508 Safety Lifecycle
 ISA84.01 Safety Lifecycle
 Detail Safety Lifecycle
CFSE Exam Preparation: Section I-1

Exercises
Safety Lifecycle
1. Explain, in general, how hazards that require a SIF for risk
reduction are identified.

2. How many safety integrity levels are defined in IEC 61511 or

ISA 84.01(select one of your choice)? What are the associated
probability of failure on demand ranges?

3. Explain the difference between conceptual design and detailed

design for SIS.

4. Provide an example of when decommissioning a safety

instrumented system could be hazardous.

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CFSE Exam Preparation: Section I-1

Exercises (Key)
Safety Lifecycle
Explain the difference between conceptual design and detailed
design for SIS.
Conceptual design involves selecting the technology (e.g., PLC
vs. Relay) and architecture (1oo2 vs. 2oo3). Detailed design
involves selecting specific components (make and model) and
wiring and/or programming the physical equipment.
Provide an example of when decommissioning a safety
instrumented system could be hazardous.
If a single SIS contains a preponderance of SIF from a unit that
is being decommissioned, but also contains 1 or 2 SIF from a
unit that will remain in service. If the SIS were completely
decommissioned with the process unit, the SIF for other process
units would no longer exist, causing a hazard.
29
CFSE Exam Preparation: Section I-1

Exercises (Key)
Safety Lifecycle
Explain, in general, how hazards that require a SIF for risk
reduction are identified.
Some functions are identified by experience, these are existing
functions which should be marked on P&ID. Others are found
by systematic creative brainstorming exercises called Process
Hazards Analyses. (PHA)
How many safety integrity levels are defined in IEC 61511 or
ISA 84.01(select one of your choice)? What are the associated
probability of failure on demand ranges?
IEC 61511 has four levels, 1,2,3 and 4. ISA S84 has three levels,
1,2, and 3. The PFD ranges are as follows:
SIL1 – 0.10.01 SIL2 – 0.01  0.001
SIL3 – 0.001  0.0001 SIL4 – 0.0001  0.00001
30