Practical Safety Instrumented Systems and Emergency Shutdown Systems for Process Industries using IEC 61511 and

IEC 61508
An ACS Engineering Ltd training workshop that introduces managers, engineers and technicians to the latest standards and practices in the application of safety instrumented systems and Emergency Shutdown systems for the protection of hazardous processes.

Objectives - what you will gain from this workshop:

1. Take away a checklist that you can use to quickly access if your plant complies with the latest international safety standards 2. Walk away with a solid fundamental knowledge of IEC 61511 and IEC 61508 which you can apply immediately to your plant 3. Ability to comply with the IEC 61511 and IEC 61508 standards thus signifying that your company is following the best available safety practices for a process company 4. Get a practical understanding of the key sections of IEC 61511 and 61508 without wading through hundreds of pages of standards documents 5. Be able to determine required SIL ratings using at least 3 different methods as listed in IEC 61511 This has the potential to save costs by avoiding needlessly high specifications for your trip systems 6. Be able to configure safety systems to minimise or avoid spurious trips and create the potential to reduce production losses. 7. Know what can be done and what should not be done with PLCs and smart sensors 8. Know how to take advantage of smart positioners and other self testing devices to reduce down time needed for proof testing 9. Have overall knowledge of the key design and procedural requirements of IEC 61511 to ensure your safety systems comply with the best international codes of practice. 10. Know how to set up function safety management procedures to meet international standards and be well prepared for independent assessments. 11. The ability to plan and integrate all stages of a safety system project.

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12. Know how Hazop studies are performed and be able to define safety system requirements during Hazop studies. 13. Know how to allocate safety tasks to both instrumented and non-instrumented protection layers to reduce dependency on a single method of protection. 14. Be able to quickly estimate feasibility and costs of safety measures during Hazop studies. 15. Take the mystery out of the IEC 61511 and 61508 Standards 16. Demonstrate personnel competency in the latest international standard 17. Gain financial advantage for your company by eliminating high installation costs 18. Gain insight into these valuable topics from an independent, unbiased, company with a significant track record in presentation of effective training solutions.

Remember that working to the highest standards of practice will help your company to find the most cost effective balance between safety and operating costs.
Certificate of Attainment *OPTIONAL FOR ON-SITE CLIENTS
IDC Workshop on IEC 61511 Safety Instrumented Systems for the Process Industries

IEC 61508

Safety Instrumented Systems Users of standards

IEC 61511

SIS Devices
Manufacturers and Suppliers of Sensors, Valves, Safety PLCs hardware and software

IDC SIS Users Workshop Process plant design teams Instrument engineers Process control systems designers System integrators Operating companies Regulatory inspectors Conformity assessors Process safety managers

There are specifically designed practical exercises, at the end of most modules. For clients that have elected to take the assessment option, at the conclusion of the workshop, the successful participants will be given a statement of attainment based on the course assessments that will confirm that they have completed this workshop successfully. The course assessment will be based on: 8 Practical exercises Class participation Two Tests given during the two days *NB. The practical exercises are standard in all workshop presentations however the assessment option is also available for on-site clients.

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The Workshop: For project managers and engineers involved with hazardous processes, this workshop focuses on the management, planning and execution of automatic safety systems in accordance with IEC 61511, the newly released international standard for process industry safety controls. (See over for background to IEC 61511). IEC 61511 has been recognised by European safety authorities and by USA based process companies as representing the best practices available for the provision of automatic safety systems. The new standard captures many of the well established project and design techniques that have been described since 1996 in ANSI/ISA standard S84 whilst introducing many newer principles based on the master standard IEC 615108. The newly released standard IEC 61511 (published in 3 parts) combines the principles of IEC 61508 and S84 into a practical and easily understood code of practice specifically for end users in the process industries. This new IDC Workshop is structured into two major parts to ensure that both managers and engineering staff are trained in the fundamentals of safety system practices. The first part of the workshop, approx the first third, provides an overview of the critical issues involved in managing and implementing safety systems. The subjects covered in the overview portion of the workshop include: Risk management principles applied to protection systems. The legal framework such as major accident hazard regulations and control of substances hazardous to health. An overview of standards IEC 61508 and 61511 An introduction to the safety life cycle as defined in IEC 61511. Process hazard analysis and its link to protection systems. The meaning of SILs and their cost implications. The problems and rewards of SIL determination Basics of safety instrumentation. Why programmable systems need special treatment Economics and cost of ownership Competency requirements and conformity assessment programmes. Conclusion: What should management be doing towards compliance? Safety authorities are now expecting companies to work to established international standards and often insist on compliance with them. For automatic safety systems the general standard IEC 61508 and the process industry version IEC 61511 describe principles for their planning, management and implementation. There is an increasing demand for conformity assessment to be carried out by independent bodies who will examine the abilities of a company to manage its safety activities. In particular, safety systems are not considered to be acceptable unless they are supported by suitable management systems with competent staff. This training workshop provides the essential grounding in IEC 61511 and its safety management principles needed to develop conformity and competency in safety systems.

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The remaining time is allocated to training of engineers and technicians in aspects of safety lifecycle practices. Some of key issues covered in this stage include; The role of HAZOP studies and hazard analysis in deciding what safety measures are needed. The training includes an outline of basic HAZOP methods and trains participants in fault tree analysis methods used to predict accident rates. Understanding safety integrity levels (SILs) and their impact on capital and operating costs. Methods for the determination of SIL requirements. This subject is known to cause difficulties and confusion in the early stages of process development projects and the subject has now been covered in depth by IEC 61511. This workshop examines the various SIL determination methods presented in IEC 61511 and provides practical exercises to ensure participants are able to carry out their own SIL determinations with confidence. Why safety PLC's are special and need to be certified for safety. Safety system architectures such as 1oo2 and 2oo3 and which versions to use to meet performance needs of reliability and availability. What IEC 61511 requires from instruments, sensors and valves to qualify them for safety applications. Are smart transmitters acceptable for safety? How can a smart positioner improve safety performance? How to perform reliability analysis to predict and verify safety system reliability and spurious trip rates. Guidelines on documentation and validation of completed installations. Essentials of maintenance and proof testing. The benefits of diagnostic systems in reducing test frequencies. The workshop manual provided with this course includes all material presented in the workshop and provides details beyond the scope of two days of training. The modular format of the manual allows our presenters to adjust the subject material covered in the two day workshop to meet the needs of participants whilst the manual will serve as a reference for future studies. Detailed Outline of the Workshop Content Module 1 - Overview of Safety Instrumented Systems for Managers" This module describes the role of safety instrumented system as part of the overall risk reduction measures that a company will typically install to deal with a hazardous process. It explains the basic technical features of a safety system and shows what tasks must be carried out to ensure that the protection measures are properly defined and implemented. The key features of safety systems are described in non-technical terms and the relevance of these features to the capital cost and operating costs are spelt out. This module then describes the developments that have resulted in a comprehensive new internationally accepted standard, IEC61511 being available specifically for use in the process industries. The module explains the scope and importance of IEC 61511 as a means to achieve and demonstrate high quality in applied safety systems. It is important at this stage to include good coverage of the existing standard ANSI/ISA S84.01 as this one of the predecessors to IEC 61511 and is the currently recognised standard in the USA for achieving compliance with OHSA regulations as applied to SIS.

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Past failures of safety systems have very often been attributed to human errors in their design and upkeep. Authorities responsible for enforcement of safety have come to the realisation that the management of all safety activities is therefore as important as the technical equipment used to carry out safety functions. This why IEC 61511 defines the management of safety life cycle activities as one of the critical issues in achieving compliance with the standards. This module outlines the requirements for management of safety life cycle activities that are spelled out in IEC 61511 and discusses issues such as third party audits and assessments, staff competency requirements and conformity assessment schemes. Practicals: In this module the practicals should take the form of a questionnaire with illustrated examples of a process problem. Questions will require knowledge of basic principles to be applied. Module 2: Introduction to IEC 61511 and the Safety Lifecycle This module presents the background to functional safety principles and then introduces IEC 615108 and IEC 61511. It explains their joint purpose and then shows the split of responsibilities between Vendors (where IEC 61508 is generally applicable) and Users (where IEC 61511 predominates). At this stage substantial coverage is given to ANSI/ISA S84.01, this being the currently accepted standard in the USA for OHSA compliance. With this background in place the module describes the safety lifecycle phases and explains key points relevant to each phase. The specific requirements of IEC 61511 are summarised Module 3: Hazop methods and hazard analysis for defining risk reduction requirements. This module includes a brief presentation on Hazop study methods for continuous and batch processes. It provides practical guidance on the identification of hazards and the ranking of risks according to severity and likelihood. Practical examples of risk matrix methods and documentation systems are provided. Module 4: Principles of risk reduction and safety allocation This module describes stage 2 of the IEC 61511 safety life cycle and provides training in the principles of recognising layers of protection and the allocation of risk reduction measures to both instrumented, and non- instrumented, protection systems. It provides detailed guidance on preparation of a typical safety requirements specification in which the individual safety functions are properly defined. Further, this module raises awareness of the key importance of Hazoping to IEC61511, but it is not training in Hazops specifically. (Please refer to our Hazops workshop for this.) Module 5: Practical SIL determination methods based on IEC 61511 This modules addresses the basic question: How can we decide the SIL ratings for our safety functions? Part 3 of IEC 61511 is dedicated to this subject. Our module here provides training in each of the methods for SIL determination described in the standard. Worked examples are presented for quantitative and qualitative SIL determination and these are followed by practical exercises to ensure participants have confidence in the methods they have studied. This module concludes with a demonstration of application software showing how the risk graph method can be systematically captured in a database package.

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Module 6: Practical SIS configurations for both safety and availability targets This module explains SIS architectures such as 1oo1 and 2oo3 and shows how the two performance objectives of safety and avoidance of spurious trips can be satisfied by the arrangement of redundant sensors, logic solvers and actuators. IEC 61511 defines constraints on the SIL ratings that can be achieved by various architectures and these principles are fully covered in this module. Module 7: Practical selection of sensors and actuators for safety duties This module trains participants to know what to look for when selecting instruments for safety. IEC 61511 requires instruments selected for safety duties to have good fail safe characteristics and must have a proven track record of good performance in safety applications. The new standard requires special provision for smart transmitters and programmable devices in general. Many companies are not aware that the instruments they have selected will not satisfy IEC 61511 and will not pass a safety audit. Module 8: Practical reliability analysis methods and programs to IEC 61511 This module shows how to carry out simple reliability calculations to evaluate the design of a safety function in terms of its probability of failure on demand and shows how to verify that the required SIL rating has been achieved. Training is provided in 1st principles using simplified reliability formula based on IEC 61508 part 6. The module shows how calculations can be checked against reference tables in IEC 61508 and how simple spreadsheet applications can be set up. The training includes a review of SIL calculation software packages with demonstrations using one or more packages. Module 9: Practical selection of safety controllers This module describes the essential characteristics of various types of safety-certified PLC's and explains why regular PLCs are not acceptable for safety duties. Practical selection issues are discussed with the aid of guideline found in IEC 61511 and involving hardware and application software. This module will support participants involved in the evaluation of available safety certified PLCs. Module 10: Practical system integration and application software for safety controllers This module reviews key stages in the hardware and software implementation activities as defined by IEC 61511. It will assist participants to plan the engineering of hardware and in the configuration of the application programs for safety controllers Module 11: Practical documentation and validation of SIS systems. This assist participants to plan the complete documentation package required for IEC 61511 safety life cycle stages. This includes document formats for the hazard identification stage, safety requirements specification and SIL determination stages. It will explain the principles of verification of each stage of the project and will then show how validation should be planned by preparing documents for testing and recording results. Module 12: Practical diagnostics and proof testing of safety instrumentation This module provides training in practical methods for proof testing and then extends to show how auto-diagnostic methods can be applied to field instruments. This module links the guidelines on diagnostic methods found in IEC 61511 to some practical examples such as partial closure testing of valves. The training shows how smart positioners can be used to reduce proof testing frequencies or improve SIL ratings.

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Background: Why IEC 61511 is important for your organisation. The newly released international standard for functional safety systems in the process industries, IEC
Origins: How IEC 61511 has become the international standard for SIS in process industries
USA Europe + USA

IEC 61508
Europe + USA

ANSI/ISA S84.01

IEC 61511615112003

ISA/S84- (IEC 61511 ISA/S842003)

Europe USA Australia Canada Africa East Asia 61511, is set to have a far reaching impact on the way automatic safety systems are managed and installed in hazardous process plants. This standard is effectively the operating companys guide to the management, planning and execution of state of the art risk reduction measures using instrumentation and control equipment. IEC 61511 effectively merges the established USA standard ANSI/ISA S 84 - 1996 with the European practices founded in IEC 61508. The American version of the new standard is due to be published as ISA 84.01-2003(IEC 61511).

Many process plants have the potential for hazardous events such as explosions, fires or toxic gas release. Sometimes a business faces a major asset loss due to a malfunction of critical equipment such as a cooling system or from sudden disturbance to the process. In such cases automatic safety shutdown systems are essential and the company and its personnel must have a high degree of confidence in the ability and reliability of the safety system to do its job. Its is equally important that authorities and the public in general are reassured that the safety systems are of the highest quality and are being continually maintained and kept in service in perfect working order. Health and safety legislation in most industrialised countries makes it compulsory for companies to prove that they have implemented the best reasonably practicable safety measures for the protection of personnel and the environment inside and outside of their plants Until recently no internationally recognised procedures existed for the management and design of automatic safety systems, now known as functional safety systems. Safety authorities have recognised that having technically sound equipment is not sufficient to provide assurance that processes are adequately protected against catastrophic events. The correct management of all activities associated with protection measures is equally critical to their success and many fatal accidents have been attributed to failure to manage safety activities. To add to the concerns, safety engineers recognised that there are increased complexities and risks associated with using computers and programmable control systems to perform the safety monitoring and trip response tasks. However, thanks to an industry wide effort across many countries consensus has been reached on a set of safety engineering principles, including those involving software and programmable devices. The newly released functional safety standard for the process industries is IEC 61511 and it is to be used in association with the general standard IEC 615108 that was first introduced in 1999. Familiarity and, ultimately, compliance with both of these standards will signify that a process company is following the best available safety practices. SUMMARY, OPEN FORUM, COMPLETE FEEDBACK SHEETS AND CLOSING

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