Course Description
This 5 day course 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.
The course manual provided with this course includes all material presented in the course and provides details beyond the scope of 5 days of training.
The modular format of the manual allows our presenters to adjust the subject material covered in the 5 day course to meet the needs of participants whilst the manual will serve as a reference for future studies.
Course Objective
Upon completion of this course, you will gain the following:
- Take away a checklist to quickly assess if your plant complies with international safety standards
- Gain fundamental knowledge of IEC 61511 and IEC 61508 for immediate application
- Ability to comply with standards, ensuring best practices for process safety
- Practical understanding of key sections of IEC 61511 and IEC 61508
- Determine required SIL ratings using three different IEC 61511 methods
- Configure safety systems to minimize spurious trips and reduce production losses
- Understand PLC and smart sensor limitations and applications
- Utilize smart positioners and self-testing devices to reduce downtime
- Apply key design and procedural requirements of IEC 61511
- Set up functional safety management procedures for international compliance
- Plan and integrate all stages of a safety system project
- Define safety system requirements during Hazop studies
- Allocate safety tasks to both instrumented and non-instrumented layers
- Estimate feasibility and costs of safety measures during Hazop studies
- Understand IEC 61511 and IEC 61508 standards without unnecessary complexity
- Demonstrate competency in international safety standards
- Reduce installation costs and improve financial efficiency
- Gain insights from an independent training provider with proven expertise
Who Should Attend?
- Instrumentation and control engineers and technicians
- Design, installation, and maintenance engineers in process industries
- Sales professionals employed by end users
- Engineering firms
- System integrators
- System consultants
Course Outline
Introduction
- What Is a Safety Instrumented System?
- Confusion in the Industry
- Technology Choices
- Redundancy Choices
- Field Devices
- Test Intervals
- Certification vs. Prior Use
- Industry Guidelines, Standards, and Regulations
- IEC 61508
- IEC 61511
Design Lifecycle
- Findings of the HSE
- Design Lifecycle
- Hazard & Risk Analysis
- Allocation of Safety Functions to Protective Layers
- Develop Safety Requirements Specification
- SIS Design & Engineering
- Installation, Commissioning, and Validation
- Operations and Maintenance
- Modifications
- Decommissioning
Process Control vs. Safety Control
- Control and Safety Defined
- Process Control - Active/Dynamic
- Safety Control - Passive/Dormant
- Separation of Control and Safety Systems
- Common Cause and Systematic/Functional Failures
Protection Layers
- Prevention Layers
- Process Plant Design
- Process Control System
- Alarm Systems
- Procedures
- Shutdown/Interlock/Instrumented Systems (SIS)
- Physical Protection
- Mitigation Layers
- Containment Systems
- Scrubbers and Flares
- Fire and Gas (F&G) Systems
- Evacuation Procedures
- Diversification
Developing the Safety Requirement Specifications
- Accidents Caused by Incorrect Specifications
- Management Systems
- Procedures
- Scheduling of Assessment
- Participation of Key Personnel
- Responsibilities Not Well Defined
- Training and Tools
- Complexity and Unrealistic Expectations
- Incomplete Documentation
- Inadequate Final Review
- Unauthorized Deviation
- IEC 61511 Requirements
- Documenting the Specification Requirements
Determining the Safety Integrity Level (SIL)
- Who’s Responsible?
- Which Technique?
- Common Issues
- Evaluating Risk
- Safety Integrity Levels
- SIL Determination Method #1 (ALARP)
- SIL Determination Method #2 (Risk Matrix)
- SIL Determination Method #3 (LOPA)
Choosing a Technology
- Pneumatic Systems
- Relay Systems
- Solid-state Systems
- Microprocessor/PLC (Software-based) Systems
- System Size and Complexity
- Communications with Other Systems
- Certified vs. Prior Use
Initial System Evaluation
- Why Analyze Systems Before Construction
- Sources of Failure Rate Information
- Failure Modes
- Modeling Accuracy
- Modeling Methods
- Impact of Redundancy
- Analysis of Relay, PLC, and TMR Systems
- Field Devices
- Fault Tolerance Requirements
- Engineering Tools for Performance Analysis
Issues Relating to Field Devices
- Importance of Field Devices
- Sensors
- Final Elements
- Redundancy
- Design Requirements
- Installation Concerns
- Wiring of Field Devices
Engineering a System
- Management Considerations
- Hardware Considerations
- Software Considerations
Installing a System
- Factory Acceptance Testing (FAT)
- Installation
- Validation/Site Acceptance Tests (SAT)
- Functional Safety Assessment/PSSR
- Training
- Handover to Operations
- Startup
- Post Startup Activities
Functional Testing
- The Need for Testing
- Establishing Test Frequencies
- Responsibilities
- Test Facilities and Procedures
Justification for a Safety System
- Safety System Failure Modes
- Responsibilities for Justification
- Justification Process
- Lifecycle Costs and Analysis
- Optimizing Safety, Reliability, and Lifecycle Costs
London UK 
Spain, Barcelona 
Rome, Italy 
New York , United States 
Paris, France