Assuring your Safety Instrumented Systems as part of your … · 2018-11-05 · Assuring your Safety Instrumented Systems as part of your ... There is an Industry requirement to improve

1ABB – United KingdomStuart Nunns

Assuring your Safety Instrumented Systems

as part of your

Process Safety Management Requirements

International TÜV Rheinland Symposium in ChinaFunctional Safety in Industrial Applications18 – 19 October 2011, Shanghai - China


� Significant Industry incidents occurring on a regular basis i.e. Texas City, Buncefield, etc

� Regulatory expectations for improving:-� Process safety management� Functional safety management

� Corporate responsibility and duty of care underpinned by shareholders, colleagues and the general public

� Links to increased process safety management (PSM) requirement relating to layers of protection

� There is an Industry requirement to improve the basis of safe operation, covering:-� Equipment Integrity� Operational Integrity� Competency development

The Need for Additional Safety Assurance


The key concepts to managing safety

Process Safety

Functional Safety

Product Safety

CompetencyAssurance


How are safety assured solutions developed?

Ultimately the end user operators are the drivers o f this requirement

� To achieve these requirements, operator’s must:-� Design and build plants to appropriate technical standards and good practices

� Operate and maintain plants using appropriate safety and qualitymanagement systems� Use competent delivery resources throughout both the project, asset and

operational lifecycle of the equipment in use� Use technology that is fit for purpose

Resulting in delivery of a world class Corporate safety,

performance & sustainability model:-

License to operate

License to operate

Improved safety performanceAvoidance of harm

Improved safety performanceAvoidance of harm

Sustainabilityof the Business

Sustainabilityof the Business

Business excellence

Business excellence

Stakeholder and public confidence

Stakeholder and public confidence


Supply chain essentials

What are the issues in delivery of assured layers o f protection?

� Rightsizing / downsizing, mergers and acquisitions

� Fragmentation of core expertise

� Sourcing credible third party providers of products and services

� Complex supply chain delivery models


Example - Complex Supply chain model

End-user Consortium

End-user Lead Org

EPC / Operator

EPC / Operator

Final Element vendorLogic Solver vendor

End-user Lead Org

End-user Consortium

Regulatory Authority


What problems does this create?

� Ownership / roles & responsibilities?

� Specifications

� Projects costs, timeframes and risk

� Terms & conditions

� Approvals & fitness for purpose

� Regulatory compliance and due diligence


Provision of an assured solution – Key Requirements

Competency Assurance� People - knowledge, experience, training

and qualifications

� Recognised third-party certifiedcompetency schemes

Process Safety� Responsibilities and ‘duty of care’

� Safe manufacturing

� Compliance with regulations

� Sustainable operations

Functional Safety� Application of appropriate safety related

technologies

� Third-party accredited and certified

� methodologies, procedures and systems

� Compliance with standards / good practice

� Compliance with the overall safety lifecycle

Product Safety� Third-party accredited and certified

� SIL capable products

� Performance guarantees


Implementation methodology

Overall installation and commissioning

planning

Overall safety

validation planning

Overall operation and maintenance

planning

Concept1

Overall scope definition2

Hazard and risk analysis3

Overall safety requirements4

Overall safety requirements allocation5

E/E/PE system safety requirements specification9

E/E/PE safety-related system

RealisationRealisation(see E/E/PE system

safety lifecycle)

10

Other risk reductionmeasures

Specification and realisation

11

Overall installation and commissioning12

Overall safety validation13

Overall operation, maintenance and repair14

Decommissioning or disposal16

Overall modification and retrofit15

Overall planning

10 Overall installation and commissioning

planning

Overall safety

validation planning


planning

Concept1 Concept1

Overall scope definition2 Overall scope definition2

Hazard and risk analysis3 Hazard and risk analysis3

Overall safety requirements4 Overall safety requirements4

Overall safety requirements allocation5 Overall safety requirements allocation5

E/E/PE system safety requirements specification9 E/E/PE system safety requirements specification9



safety lifecycle)

10 E/E/PE safety-related system


safety lifecycle)

10



11 Other risk reductionmeasures


11

Overall installation and commissioning12 Overall installation and commissioning12

Overall safety validation13 Overall safety validation13

Overall operation, maintenance and repair14 Overall operation, maintenance and repair14

Decommissioning or disposal16 Decommissioning or disposal16

Overall modification and retrofit15 Overall modification and retrofit15

Overall planning

10

IEC 61508

Decommissioning8

7 Modification

Operation & maintenance6

Installation, commissioning

and validation5

Design & engineering

of the SIS 4

Allocation of

safety functions2

Safety requirements

specification of the SIS3

Hazard & risk analysis1

Ver

ifica

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9

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Decommissioning8 Decommissioning8

7 Modification7 Modification

Operation & maintenance6 Operation & maintenance6


and validation5


and validation5


of the SIS 4 Design & engineering

of the SIS 4

Allocation of

safety functions2

Allocation of

safety functions2

Safety requirements


Safety requirements


Hazard & risk analysis1 Hazard & risk analysis1

IEC 61511

Design & Development of other means of risk

reduction





and validation5


and validation5



of the SIS 4

Allocation of

safety functions2

Allocation of

safety functions2

Safety requirements


Safety requirements



Ver

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9

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and validation5


and validation5



of the SIS 4

Allocation of

safety functions2

Allocation of

safety functions2

Safety requirements


Safety requirements



IEC 61511


reduction

Who?

When?

Where? What?

Why?


The Detail - Processes & Deliverables - 1

Process Safety� Hazard Identification

� Risk assessment & Quantification

� Achievement of ‘ALARP’

� Identification of Protective layers

� SIL determination

� Design and engineering of safety instrumented syste ms

� Provision of evidence supporting the basis of safet y

� Requirements to operate, maintain and modify



Functional Safety

Providers of an engineered instrumented safety syst em and ‘Other’technology solutions as part of your basis of safet y:

� Ensuring compliance to good practice standards i.e, IEC 61511� Using certified:-� Safety products

� Logic Solver� Field Instruments� Final elements

� Engineers� Organisations

� Mapping the appropriate phases of the IEC 61508-615 11 safetylifecycle to the scope of supply



Product SafetySuppliers of safety-instrumented products:-

� Implementing certified processes for the design and engineering ofsafety products – preferably Third party SIL capable

� Providing certified (to IEC 61508) product performa nce – Third partySIL capable

� Continual investment in next generation, best pract ices, meetingmarket requirements and existing installed base

� Providing after sales support and sustainability of the installed base



Competency Assurance

In respect of suppliers:-� Demonstrating long term commitment to the global safety market

� Providing significant investment and development of people for global delivery

� Ensuring staff have adequate and appropriate:

� Training

� Experience

� Knowledge

� Qualifications

� Actively involved in industry focus groups and standards

� Having processes and procedures to manage and deliver succession planning

� Ensuring continued professional development of all staff


So what has to be done?

� Integrating the 4 key concepts

� Discharging responsibilities to competent organisat ions

� Mapping the compliance requirements to the IEC 6150 8 Lifecycle

� Seamlessly integrating PSM with FSM

� More importantly:Providing an overall assured safety solution for SI S


Safety Lifecycle Model – Pre-Design Risk Assessment

� Process Safety Management Systems

� Behavioural Safety & Culture

� Process Hazard Review

� Lifecycle Hazard Studies (including HAZOP 1-6)

� Pressure Relief

� Mechanical Integrity

� SIL Determination

� Hazardous Area Risk Assessmentand Classification


planning

Overall safety

validation planning


planning

Concept1








safety lifecycle)

10



11






Overall planning


planning

Overall safety

validation planning


planning

Concept1 Concept1








safety lifecycle)



safety lifecycle)

10





11






Overall planning

10

IEC 61508


Safety Lifecycle Model – Design & Engineering

� SIS Delivery

� Application specific solution

� SIL Achievement

� Specification

� Detailed design

� Realisation (Total Solution)

� TUV Certified Engs

� TUV Certified Safety Centres

� Commissioning

� Validation


planning

Overall safety

validation planning


planning

Concept1








safety lifecycle)

10



11






Overall planning


planning

Overall safety

validation planning


planning

Concept1 Concept1








safety lifecycle)



safety lifecycle)

10





11






Overall planning

10

IEC 61508


Safety Lifecycle Model – Operations and Maintenance

� Organisational Culture / Change

� Human Reliability Assessment

� Safety Critical Procedure Assessment

� Staffing Levels and Workload Assessment

� Pre Start-up Safety Review

� Legacy Systems Review

� Control Room Performance Assessment

� Alarm Management Health Check

� Safe Systems of Work

� Management of Change

� Mechanical Integrity

� Incident Investigation Support


planning

Overall safety

validation planning


planning

Concept1








safety lifecycle)

10



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Overall planning


planning

Overall safety

validation planning


planning

Concept1 Concept1








safety lifecycle)



safety lifecycle)

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11






Overall planning

10

IEC 61508


Safety Lifecycle Model – Operations and Maintenance

� Reliability and Operations Improvement

� Modifications , upgrades

� Brownfield project delivery

� 24/7 Service Level Agreements

� TUV Certified service organisation

� Performance assurance

� Testing and repairs

� Operating and Maintenance Procedures


planning

Overall safety

validation planning


planning

Concept1








safety lifecycle)

10



11






Overall planning


planning

Overall safety

validation planning


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Concept1 Concept1








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safety lifecycle)

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IEC 61508


Introduction to the ABB Assured Solution

Process Safety

Functional Safety

Product Safety

Competency Assurance

� Global Footprint

� Certified Organisations

� Certified Products

� Certified Engineers

� Complete lifecycle compliance


planning

Overall safety

validation planning


planning

Concept1








safety lifecycle)

10



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Overall planning


planning

Overall safety

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Concept1 Concept1








safety lifecycle)



safety lifecycle)

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11






Overall planning

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IEC 61508

Decommissioning8

7 Modification

Operation & maintenance6


and validation5


of the SIS 4

Allocation of

safety functions2

Safety requirements


Hazard & risk analysis1

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Allocation of

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Allocation of

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Safety requirements


Safety requirements



IEC 61511


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and validation5



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Allocation of

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Safety requirements


Safety requirements



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Allocation of

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Allocation of

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Safety requirements


Safety requirements



IEC 61511


reduction

Seamless Integration of the key concepts to a best practice delivery model


How does ABB deliver safety assured solutions?

� Global footprint via Safety Execution Centres (SEC’s)

� Design, engineer and integrate using a third party certified functional safety management system

� Provide both process safety and functional safety consultancy

� Provide full service support

� Deploy certified competent staff

� Provide complete services and deliverables for all the phases of the IEC 61508/61511 lifecycle


SEC delivery locations

ABB´s assured solution global delivery footprint


Conclusions

The ABB Methodology:-� Deliver the whole safety lifecycle on a global approach� Robust basis of safety developed� Assured protective systems solutions� Traceable, auditable compliant systems and products� Competency assurance

The ABB Assurance:-� Meeting your regulatory and legal requirements� Supporting your ability to demonstrate duty of care� Facilitating your Stakeholder confidence� Delivering ‘Fit for purpose’ Technology, Solutions and Service Support

Assured and certified products, services, delivery and execution

Documents

Assuring your Safety Instrumented Systems as part of your … · 2018-11-05 · Assuring your Safety Instrumented Systems as part of your ... There is an Industry requirement to improve