Functional Safety in Process Technology

Transcription

1 Functional Safety in Process Technology with the Safety Standard IEC Four day workshop with optional qualification as Functional Safety Certified Engineer Application (FSCEA) including demonstration tools for protective circuit calculations New Workshop Modules at TÜV NORD: We are very pleased to announce our Workshop Modules on the subject of Functional Safety for Process Engineers. The focus will be on the revised standard IEC 61511, which is mainly aimed at process industries, including the chemical industry, refineries, oil and gas extraction, paper manufacturing, conventional electricity generation and others. Following attendance at all the Workshop Modules, there is the option of taking a test and qualifying as a certified Functional Safety Certified Engineer Application (FSCEA). IEC describes the use of safety instrumented systems (SIS) in process industries, and in particular the activities that are needed within the safety life cycle in order to fulfil the minimum requirements for a SIS. This workshop is particularly aimed at the following groups: Engineers from the areas of product safety and safety management Users and designers of safety instrumented systems Process engineers working on the development and testing of safety instrumented systems Managers who need to know more about functional safety and IEC Standard Quality Management Representatives who are responsible for fulfilment of IEC Those attending the second and third day of the workshop also receive demo versions of support tools for calculation of protective circuits. The number of participants is limited to 20. Applications are possible until the Workshop is full. Please either complete the attached form and send by Fax to or register at nord.de/. We will be happy to answer your questions either by phone on or by at bpfuff@tuev nord.de.

2 Workshop Content Module 1: (one day) Functional Safety Management (FSM) Life Cycle Model from concept through hazard and risk analysis up to decommissioning Manufacturers and operators of safety relevant technical equipment and products are obligated by German product safety legislation (GPSG) and by the German Ordinance on Industrial Safety and Health (BetrSichV) to develop, build and operate their technical systems according to the state of technology as regards all aspects of safety. The burden of proof in case of incident or damage is on the erector or operator of a technical plant. Workshop Module 1 provides an overview of the boundaries of the areas of Furnaces (IEC 50156), Safety of Machinery (ISO 13849) and the Process Industry (IEC 61511), and there is also a presentation of the standards and directives that have to be applied. The Module also includes the procedures required by the standards for development, maintenance, testing and modification activities. The necessary responsibilities of employees, requirements for the competence of the persons involved, organisational aspects and knowledge of legal aspects and the possible consequences of failure of process control safety systems, consisting of field devices, control devices, hardware and software are discussed, together with the use of the four eyes principle over the entire life cycle through verification of work products by a second person who was not directly involved in the same work step. In addition, the factors involved in installation of a Functional Safety Management (FSM) System are considered, taking the tasks/roles of the persons participating in the process such as the Safety Manager and Safety Coordinator into consideration. The entire life cycle of a technical plant, from concept through hazard and risk analysis up to decommissioning, are clarified based on practical exercises. Representative examples are used in order to intensively consider the methods recommended by IEC for interdisciplinary determination of the Safety Integrity Level SIL by means of risk graph and Layer Of Protection Analysis LOPA and for extrapolation of the resulting safety requirements.

3 Module 2 (two days): Design of Safety Instrumented Systems Measures when using devices in safety systems, requirements for the selection of prior use components, determination and analysis of failures in process control protection systems and calculation of protective circuits according to IEC In order to ensure that safety related protective systems are robust, IEC requires measures to be taken against systematic and random failures and also measures in relation to fault tolerance. This means that these measures must be considered during the design phase of each safety system/safety instrumented function. Based on practical examples, Workshop Module 2 shows how it is possible to avoid systematic failures in safety systems by avoiding use of incorrectly dimensioned components and/or unsuitable materials for the connection to the process etc. A difference is made between systematic failures which can be located in the subsystem itself, and systematic failures which can result from installation of the subsystem into a specific item of plant or equipment. As a measure against random failures, IEC requires the probability of failure of a safety system to be below a specified value. When designing a safety instrumented system, basic requirements are set as regards determination of the probability of failure on demand / probability of dangerous failure per hour (PFD avg / PFH) of protective circuits. In particular, a difference has to be made between the system level and the subsystem levels. The entire system, consisting for example of a sensor, logic and actuator must achieve the required safety integrity level of the safety function. All components, including the relevant software components which contribute to risk reduction in the performance of a safety function, must be regarded as a whole. Therefore the SIL capability of each component must be sufficient for the SIL of the function. Manufacturers, planners and operators of protective circuits are faced with various different tasks in order to demonstrate risk reduction and must answer the following questions: What quantitative requirements are set by standards IEC and ISO13849? How are these linked to the Safety Integrity / Performance Level (SIL/ PL)? What are the effects of the different safety architectures and which ones are required? How are failures based on a common cause taken into consideration? How can the failure probabilities PFD avg, PFH of protective circuits be determined? What are the safe failure fraction SFF and the diagnostic coverage DC? How are test intervals and repair times taken into consideration and optimised? How can tools support solution of tasks when calculating the failure behaviour of protective circuits?

4 In the last section of this module, the requirements for measures in relation to the necessary failure tolerance depending on the SIL to be achieved are considered in relation to possible protective circuit hardware architectures. The object of Workshop Module 2 is to identify answers and solutions to the above questions. Particular emphasis is placed on determination by the workshop participants themselves of the quantitative values required by the standards, among other things with the support of tools. In this workshop, the requirements of IEC regarding prior use of components are considered in greater detail. Fulfilment and implementation of the requirements in practice are particularly important and are clarified based on examples. Module 3 (one day): SIS Software and Documentation Requirements for the development of SIS software and project specific documentation Going beyond previous software quality standards, IEC sets further software related requirements which focus on functional safety. This module is concerned with the three types of software (application software, utility software and embedded software) and the three language types (fixed programming languages, limited variability programming languages and full variability programming languages) used to create the software. The requirements of IEC regarding SIS software are clearly described. A further important component in the development of SIS is the documentation. IEC requires that the necessary information is available and is documented in such a way that all phases of the life cycle can be implemented effectively and that verification, validation and measures for assessment of the functional safety can be efficiently performed. This module discusses the documentation requirements as set out in IEC clearly and in detail. At the end of the module there is a question and answer session in preparation for the examination.

5 Module 4 (half a day): Qualifying Examination as Functional Safety Certified Engineer Application (FSCEA) Participants who so wish can register for the Qualifying Examination. The prerequisite for this is attendance at the modules 1 3. Following successful completion of the examination, you will receive your personal FSCEA Certificate from TÜV NORD Systems. The examination questions are set in German and can be answered in German, and the training modules are held in German. The Certificate is valid for three years and can be extended for a further three years following attendance at a follow up Workshop with re examination. In order to qualify for advanced certification as a Functional Safety Certified Coordinator Application or Consultant Application (FSCCA) or a Functional Safety Certified Manager Application (FSCMA) you must demonstrate at least two or four years of professional experience with relevant safety projects and must also have successfully passed a qualification audit performed by TÜV NORD. Further information is available in our flyer IEC Personal Certification.