Professional Documents
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Chris OBrien
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Chris OBrien
Chris O'Brien is a Partner with Exida Consulting. He has over 20 years experience in the design, manufacturing and marketing of process automation, reserve power systems, and safety related equipment. He focuses on supporting new and existing customers with their implementation of the IEC 61508 and IEC 61511 functional safety standards as well as reliability analysis for mechanical devices. He was formerly Vice President of the Power Systems Business Unit of C&D Technologies, a business that specialized in the design and implementation of high reliability back up power systems. Prior to that, he was with Moore Products/Siemens Energy and Automation where he held several positions including General Manager of the Instrumentation Division. Chris is the author of Final Elements and the IEC 61508 and IEC 61511 Functional Safety Standards and has been awarded 5 patents, including a patent of the industry's first safety rated pressure transmitter. He has a Bachelors of Mechanical Engineering from Villanova University.
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Topics
1. The Application of IEC 61511 to Industrial Turbines 2. Demonstrating compliance with regulations 3. Strategies for effective implementation of IEC 61511 4. Questions
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Application Standards
Customer Expectations
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North America
South America
Europe
Asia
ROW
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North America
South America
Europe
Asia
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North America
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Asia
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Demonstrating Compliance
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Less likely to miss a key step if you are following a step by step method Common, or known mistakes are explicitly addressed
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Copyright Exida Consulting LLC 2011 cobrien@exida.com / 267-261-1500 12
Hazard Identification
Safety Requirements
SIL Verification
SIL Sustain
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Analysis
Process Hazard & Risk Analysis [Clause 8] Allocate Safety Function to Protection Layers [Clause 9] SIS Safety Requirements Specification [Clauses 10 & 12] SIS Design and Engineering [Clauses 11 & 12]
Verification
FEED
Concept Design & Build Test Install Validate Proof Test Manage
Clause 7 & Clause 12.7
Realisation
SIS FAT [Clause 13] SIS Installation & Commissioning [Clause 14] SIS Safety Validation [Clause 15] SIS Operation & Maintenance [Clause 16] SIS Modification [Clause 17] SIS Decommissioning [Clause 18]
Clause 5
Clause 6.2
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Operation
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Compliance Requirements
SIL Capability
Compliance
Architectural Constraints
Probability of Failure
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Meeting Requirements
SIL Capability
Architectural Constraints
Probability of Failure
Strength SIL Capability Probability of Failure Architecture Constraints Strength against systematic failure Strength against random failure Strength against undetected failures
Copyright Exida Consulting LLC 2011 cobrien@exida.com / 267-261-1500
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Effective Implementation
Benchmark Study Gap Resolution Plan Develop Project Functional Safety Management Plan System Design Implementation Operation and Maintenance
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Copyright Exida Consulting LLC 2011 cobrien@exida.com / 267-261-1500
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SIS Software Verification SIS Factory Acceptance Test SIS Installation and Commissioning SIS Validation SIS Operation and Maintenance SIS Modification and Decommissioning SIS Documentation
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Typical Gaps
No Structured Process No Agreed Upon Tolerable Risk Poor Communication Across Organizations Missing or Incomplete Documentation Non SIL Rated Equipment Not Including All Components Unrealistic Modeling Assumptions Incorrectly Modeled Shared Equipment
Copyright Exida Consulting LLC 2011 cobrien@exida.com / 267-261-1500
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SafetyLifecycleActivity
Establish a Process
General
PlantPlantOwner
SafetyManagement SafetyLifecycleActivity
PlantPlantOwner PlantPlantOwner
Components
GasTurbine Assessment RiskAssessment SILSelection SafetyRequirementSpecification (SRS) SISDesign SILVerification SISSoftwareSRS SISSoftwareVerification SISFactoryAssessmentTest(FAT) Exida Exida Exida Exida Exida Exida Exida Exida Documentation OEM OEM OEM OEM OEM OEM OEM OEM SteamTurnine Assessment TBD TBD TBD TBD TBD TBD TBD TBD Documentation OEM OEM OEM OEM OEM OEM OEM OEM Assessment Exida Exida Exida Exida Exida Exida Exida Exida HRSG Documentation OEM OEM OEM OEM OEM OEM OEM OEM Assessment Exida Exida Exida Exida Exida Exida Exida Exida BOP Documentation EPC EPC EPC EPC EPC EPC EPC EPC
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VALIDATION
V
V
Conceptual Design
V
Internal Integrated Testing
V V
Hardware Detailed Design
V V
Software Configuration
Hardware Build
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Group Procedure
Process description for relevant phase Inputs required Outputs delivered
Project Plan
Tracking document for each project Who, what, when, where, how Sign-offs
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Project Plan
Analysis
Design
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Provides measures of protection against random hardware failures and systematic design failures
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Copyright Exida Consulting LLC 2011 cobrien@exida.com / 267-261-1500 28
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MFG 2
SIL 3
Up to 2oo3
SIL 3 Certified
Not Addressed
MFG 3
SIL 3
Up to 2oo3
SIL 3 Certified
Not Addressed
MFG 4
SIL 3
Redundant 1oo2
Not specified
2oo3 Trip Block, FE not addressed 2oo3 Trip Block, Showing 2oo3 FE, but 1 valve is the control valve 2oo3 Trip Block, FE not addressed
MFG 5
SIL 3
Up to 2oo3
Not specified
MFG 6
SIL 3
Up to 2oo3
SIL 3 Certified
MFG 7
SIL 3
Up to 2oo3
SIL 3 Certified
Not Addressed
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Neglecting to account for mission time Neglecting to account for Beta (common cause)
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Slide 35
Steam turbine shown instrumented with control loop and safety loop. The safety loop can de-energize both the shutdown valve and control valve.
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Slide 36
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7.69E-04 year +
1.475E-03 year
SIS PFDAVG (1oo1) BPCS A/CV Failure 2.0E-02 3.53E-02 * = year Branch 2
7.06E-04 year
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Slide 38
100
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Slide 39
System Design
Select SIL certified equipment when possible Make provisions for automatic testing
Diagnostic Proof Testing
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Comments
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Implementation
Ensure all parties clearly understand their roles and responsibilities
Examples
Does the system integrator have a software specification and validation plan Is the safety PLC physically configured per the OEMs requirements for the given SIL level Is the delivered PLC code exactly the same as the FAT code
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Questions
Global Network of Expertise
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