Introduction to Functional

Safety
Objective
• Objective of this course is to train the Professionals regarding Basic
Principles of Functional Safety specifically, Safety Instrumented
Systems in the Process Industry.
• Any Safety Fundamentals course/ Certification aims to establish a
group of Functional Safety engineers/experts with a common set of
knowledge according to IEC 61508, IEC 61511 etc.
During the Session
• Feel free to answer you phones but please turn it to silent!
• Feel free to ask questions at any time. But don’t expect an answer
right away.
• We will be taking short breaks to refresh
Introduction to Functional Safety
• A review of the Major Accidents
• Texas City Disaster 1947
• Bhopal 1984
• Toulouse Fertilizer Complex 2001
• BP’s Texas City Refinery Explosion (Report)
• Deep water horizon (Watch Movie)
• A list of accidents will be shared for self study
Is safety Expensive?
• There's an old saying that “if you think safety is expensive, try an
accident. Accidents cost a lot of money. And, not only in damage to
plant and in claims for injury, but also in the loss of the company's
reputation.”
Dr. Trevor Kletz
• Accidents cost more than 10x the investment in the process
• Accidents with serious impact still happen today
• Training is one way to help people become more aware and
knowledgeable about safety
Safety Definition
• According to ISO/IEC Guide 51 the term “Safety” is defined as
“Freedom from risk which is not tolerable”
What is Risk?
• According to ISO/IEC Guide 51 the term “Risk” is defined as
“Combination of the probability of occurrence of harm and the
severity of that harm”
Legal Status IEC 61511
• Standards are never legally binding, they are used merely for guidance
but…
• Since its release (2003) IEC 61511 is considered State-of-the-Art or Good
Engineering Practice
• State-of-the-Art means IEC 61511 is
• Technically feasible and applicable
• Organizationally possible to plan
• Economically feasible
• State-of-the-Art is a legal term in Europe and is the only thing court looks
at
• This makes it almost impossible not to comply to IEC 61511 when it comes
to safety instrumented systems
Laws and Directives
• In Europe
• Medical Directive (Deals in Medical Devices within the European Union)
• Lift Directive (Governs most passenger and goods lifts)
• Seveso II Directive (Chemical, Industrial Risk and Biotechnology)
• Machinery Directive (Concerning Machinery and certain parts of Machinery)
• ATEX Directive (Potentially explosive environment)
• PED Directive (Pressure Equipment Directive)
• In Europe
• EPA (Environment Protection Agency) Risk Management Program -40 CFR part
68
• OSHA (Occupational Safety and Health Agency); Process Safety Management
Laws in Pakistan
• There is no independent legislation on occupational safety and health
issues in Pakistan. The main law, which governs these issues, is the
Chapter 3 of Factories Act, 1934. All the provinces, under this act,
have devised Factories Rules. Khyber Pakhtunkhwa and Sindh have
enacted the Factories legislation in 2013 and 2016 respectively.
• Other laws could be find on the link Below:
• https://paycheck.pk/labour-laws/health-safety-at-work/occupational-
safety-and-health
Layers of Protection
Safety Integrity Level - SIL
• SIL is how we measure the performance of safety functions carried
out by safety instrumented systems
• SIL has 3 sides to story
• Process Owners
Which Safety Functions do I need and how much SIL do I need?
• Engineering Companies, System Integrators, Product developers:
How do I build SIL compliant safety devices, functions or systems?
• Process Operators:
How do I operate, maintain and repair safety functions and Systems to
maintain the identified SIL Levels?
Safety Integrity Level - SIL
• There are 4 SIL levels in IEC 61511 and IEC 61508 OH Wait!! What is a
• SIL 1,2,3 and 4 Safety Function??

• Important SIL properties

• Applies to the complete Safety Function/Loop.
• There are technical and non-technical requirements defined per SIL Level
• Higher SIL means
• Stricter Requirements
• The Safety Function fails less and is thus more available
Safety Instrumented Function
• The Function performed by Safety Instrumented System is known as
Safety Instrumented Function
• Number of SIFs could be performed by a single SIS
• It is designed to prevent or mitigate a hazardous event by taking a
process to a tolerable risk Level
Probability of Failure on Demand (PFD)
• The probability a device will fail to perform its required function when
it is called upon to do so
• The average PFD
(PFDavg- failure rate of all
elements within a Safety
Instrumented Function) is
used for SIL evaluation
• Average is for one year time
Safety Instrumented Systems States
• A safety Instrumented system can be in 4 different states
• OK: No internal failures
• Safe: the safety instrumented systems fails in a way that the safety function is
carried out without a demand
• Dangerous: the safety instrumented systems fails in a way that the safety
function cannot be carried out in case of a demand
• Intermediate: Safety function can still be carried out despite one or more
internal safety instrumented systems failures
SIS versus Process
SIS States Process to be Protected

OK Process is available

Safe Process has tripped

Dangerous Process is available but not protected

Intermediate Process is available, SIS is available, but it is time to

repair it
SIS Failures
• SIS can fail because of…
• Random Hardware Failures
• Common Cause hardware failure
• Systematic Failures

• Each of these failures can manifest itself in two ways

• Permanent – Exists always
• Dynamic – Exists only under certain circumstances. Dynamic failures are
difficult to test for
• Any of these failures put the SIS into a specific system state (Safe,
Dangerous or intermediate)