SIL Assessments and Verifications - M+W Process Automation

M+W Process Automation
SIL Assessments and Verifications in the

Process Industry
Ein Unternehmen der M+W Group

A Company of the M+W Group
Bram Van Liefferinge

Doc.-Vers.: 16
SIL Assessments and verifications in the

process industry
Content
IEC 61511
Company Presentation
Doc.-Vers.: 16
M+W Process Automation A Company of the M+W Group

TV FSE 625/07
Project Engineer
Head Functional Safety Departement
Doc.-Vers.: 16
SIL Process Industry

IEC 61511
Functional Safety - Safety Instrumented Systems for the Process Industry
Who?
Why?
What about?
How?
Doc.-Vers.: 16
IEC 61508 >< IEC61511
IEC 61508
=> Manufacturers & Suppliers
IEC 61511
=> End Users & System Integrators
Doc.-Vers.: 16
Who?
Seveso II Directive:
control of major-accident hazards involving dangerous substances
High level Seveso company
Low level Seveso company
Kind of substance
Amount of substances
Seveso locaties in Belgium:
173 H
194 L
Doc.-Vers.: 16
Why?
Seveso Directive:
Take all necessary measures and show to inspecting authorities that all necessary
measures are fullfilled.
=> Which measures and why
High level of protection
=> Codes of good practise: IEC 61511
PAM:
Preventive Active Measures
Belgium: Seveso
MES 3-audit
Func. Safety: PAM
Doc.-Vers.: 16
What about?
Risk Reduction with:
Sensor
SIS
Logic
Doc.-Vers.: 16
Actor
How?
Lifecycle concept
How do I build an SIS?
How do I keep my SIL / Risk reduction?
Doc.-Vers.: 16
Hazard and Risk Analysis

Seveso: To take all necessary measures and to show inspecting authorities
that all necessary measures are fullfilled.
Identify Hazards
Define Risks
Without safeguards!
Risk = Probability x Severity
Define necessary risk reduction
10
Doc.-Vers.: 16
Allocation of Safety Functions

to Protection Layers
Risk unacceptable?
Identify existing safeguards
Define additional safeguards
Intrinsic Safe Design
Mechanical Protection Layer
Instrumental Protection Layer (SIL)
Passive protection layers (dyke)
Human intervention
S
S
A
SIL
!
D
E
ESS
LOPA, matrix, risk graph
11
Doc.-Vers.: 16
Safety Integrity Level

Measure for the reliability of the SIS (PFD)
SIL3 much harder then SIL1
RRF = 1 / PFD
12
Doc.-Vers.: 16
IEC 61511 Lifecycle
13
Doc.-Vers.: 16
Safety Requirements Specification
Why is this so important?
=> Emphasis government: PAM
14
Doc.-Vers.: 16
SIF Safety Requirement Specification
Functional requirements
Integrity requirements
General concept
PFD-calculations to determine
SIF specification
Test Interval
SIL
=> Safety
STL (Spurious Trip Level)
=> Availability
PFD-calculation
Design & Engineering
15
Before basic/detail/software engineering
Basis for documentation
Basis for validation
Doc.-Vers.: 16

IEC 61511 & PAM
16
Trip setting
Safe operating limit + argumentation
Response time requirements
Diagnostics
Reset functions
Additional risks because of trip?
Fail actions
Demands rates
Test interval and repair times
When is the function active? (start up, normal operation,...)
...
Doc.-Vers.: 16
Engineering
Allocation of safety functions
=> Risk Reduction & PFD
=> Functionality
17
Doc.-Vers.: 16
SIL Verification
Architectural Constraints
HFT
SFF
PFDavg
Failure rate (Lambda )
Architecture
Diagnostic Coverage
Common cause (Beta )
Test Interval (TI)
Mean time to repair (MTTR)
Demand mode
=> SIL
PFD (SIF)
18
Doc.-Vers.: 16
Failure Rates
Sources:
19
Vendor data (certified or not)
Oreda
Exida
...
Doc.-Vers.: 16
Hardware Fault Tolerance (HFT)
How many hardware failures may occure without loss of the safety function?
1oo1
1oo2
1oo3
2oo3
SFF from SIL certificate vendor
20
Doc.-Vers.: 16
IEC 61508
IC/Software => Type B!
SIL2 application simple pressure measurement
=> 1oo1
SIL2 application temperature measurement smart
=> 1oo2
21
Doc.-Vers.: 16
IEC 61511
Dominant failure = safe failure
SIL2 application simple pressure measurement
=> 1oo2
SIL2 application temperature measurement smart
=> 1oo2
22
Doc.-Vers.: 16
IEC 61511 Loophole
HFT may be reduced by one if:
Hardware of the device selected on prior use basis
Only process related parameters may be adjusted
Parameters protected
SILSIF < SIL 4
23
Doc.-Vers.: 16
PFDavg: Architecture
1
PFD1oo1 DUTI
2
PFD1oo2
2DUTI2
1
DUTI
3
2
PFD 2oo2 DU TI
PFD 1oo3
PFD
24
2oo3
3DU TI3
4
2
DU
1
DU TI
2
1
T I DU T I
2
2
Doc.-Vers.: 16
PFDavg: Diagnostic Coverage

Sensors
External comparison => 90% du detected
Logic
PLC
Longer Test Interval!
DC > 99%
Relay Systems
DC = 0
Final Elements
On/Off valve: DC=0
Partial Stroke testing: 60%
25
Doc.-Vers.: 16
PFDavg: Common cause

IEC 61511-1 3.2.6.1 common cause failure
failure, which is the result of one or more events, causing failures of two or more
separate channels in a multiple channel system, leading to system failure
determined by:
Separation of channels
Diversity
Procedures / Training / Test methods
Environment
...
can have a significant impact!
estimation:
Conservative (10%)
Tables IEC 61508
Exida
26
Doc.-Vers.: 16
PFDavg: TI, MTTR and Demand Mode
Test Interval
Mean Time To Repair (MTTR)

Limited influence
Spare available!
Repair must be possible!
Demand Mode
Process => Normally Low Demand Mode
27
=> PFD
Doc.-Vers.: 16
1
PFD1oo1 DUTI
2
SIL Verification
PFD Calculations
=> PFD (SIF) => SIL Achieved!
28
Doc.-Vers.: 16
IEC 61511 Lifecycle
29
Doc.-Vers.: 16
Conclusion
SIL Assessments & Verifications are not easy!
No experience? Get help!
30
Doc.-Vers.: 16
Organization of the M+W Group
M+W Group GmbH

Dr. Hannes Rosenthaler
Juergen Wild (Speaker of the Board)

100%
Facility Solutions
Process Solutions
Product Solutions
3.306 Employees
825 Employees
224 Employees
M+W Asia Limited,

Singapore

GmbH, Ludwigshafen
M+W Process Industries
GmbH, Stuttgart
Chemical
Pharmaceutical
Biotech
Automotive
Food and Beverage
Water / Waste Water
Oil and Gas
Energy
M+W Products GmbH,

Stuttgart
Juergen Wild
Herbert Blaschitz
Electronics
Flat Panel Displays
Photovoltaic
Energy /
Renewable Energy
Juergen Wild
Clean Room Systems

Clean Room Products
Others
Fac.Eng.GmbH
Real Estate
IT / Caatoosee (51%)
NumberAnzahl
of employees
der Mitarbeiter
of the M+W
der M+W
Group:
Group:
4.5244.524
Annual
- Gesamtumsatz
sales revenue
ca.
approx.
1,73 Mrd.
1,73billion
31
Doc.-Vers.: 16
Organization Process Solutions
Business Unit Process Solutions

Head: Juegen Wild
M+W Process Automation GmbH

Headquarters: Ludwigshafen
M+W Process Industries GmbH

Headquarters: Stuttgart
470 Employees, Sales 2008: 63 M
386 Employees, Sales 2008: 95 M
Automation
Process Plant Engineering
Chemicals
Pharmaceuticals
Food and Beverage
Biotech
Water / Waste Water
Oil and Gas
Energy
Automotive
Biotech
Pharmaceuticals
Chemicals
Food and Beverage
Cosmetics
Management:
Andreas Bieber, Franz Greisberger &
Henning Hammerstaedt
Regional Office B + NL
50 Employees
Locations B: Melsele, Wavre,
Locations NL: Breda
Management:
Dr. Tobias Luecke,
Hermann Schwarzkopf
Management:
Stephan Hoste
32
Doc.-Vers.: 16
Consulting
Start-Up
Design
Basic
Engineering
Training
Detail
Engineering
Service
Specification
Validation
Control Cabinet
Mounting
Installation
33
Doc.-Vers.: 16
Project Management
Supply
Management
PLC and DCS

Robot
Programming
Manufacturing
&
Business
Integration
Thank you for your attention!

If you have any questions...
Ein Unternehmen der M+W Group

A Company of the M+W Group

Eric Vohy
Version: May 2010
Doc.-Vers.: 16

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M+W Process Automation

SIL Assessments and Verifications in the

Ein Unternehmen der M+W Group

Bram Van Liefferinge

SIL Assessments and verifications in the

M+W Process Automation A Company of the M+W Group

M+W Process Automation

M+W Process Automation A Company of the M+W Group

SIL Process Industry

M+W Process Automation A Company of the M+W Group

IEC 61508 >< IEC61511

M+W Process Automation A Company of the M+W Group

M+W Process Automation A Company of the M+W Group

Preventive Active Measures

Func. Safety: PAM

M+W Process Automation A Company of the M+W Group

M+W Process Automation A Company of the M+W Group

M+W Process Automation A Company of the M+W Group

Hazard and Risk Analysis

Define necessary risk reduction

M+W Process Automation A Company of the M+W Group

Allocation of Safety Functions

LOPA, matrix, risk graph

M+W Process Automation A Company of the M+W Group

Safety Integrity Level

M+W Process Automation A Company of the M+W Group

IEC 61511 Lifecycle

M+W Process Automation A Company of the M+W Group

Safety Requirements Specification

Why is this so important?

=> Emphasis government: PAM

M+W Process Automation A Company of the M+W Group

Safety Requirements Specification

SIF Safety Requirement Specification

STL (Spurious Trip Level)

Before basic/detail/software engineering

Basis for documentation

Basis for validation

M+W Process Automation A Company of the M+W Group

Safety Requirements Specification

Safe operating limit + argumentation

Response time requirements

Additional risks because of trip?

Test interval and repair times

When is the function active? (start up, normal operation,...)

M+W Process Automation A Company of the M+W Group

Allocation of safety functions

=> Risk Reduction & PFD

Safety Requirements Specification

M+W Process Automation A Company of the M+W Group

Failure rate (Lambda )

Common cause (Beta )

Test Interval (TI)

Mean time to repair (MTTR)

M+W Process Automation A Company of the M+W Group

Vendor data (certified or not)

M+W Process Automation A Company of the M+W Group

Hardware Fault Tolerance (HFT)

SFF from SIL certificate vendor