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[W24]Safety:

Is it a common approach for machine and process ?

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Safety – Is it a common approach for Machine & Process?

Functional Safety :-

• fundamental to the enabling of complex technology used for safety-related systems.

• assurance that the safety-related systems will offer the necessary risk reduction required to achieve safety

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What is Functional Safety ?

Functional safety is part of the overall safety that depends on a system or equipment operating correctly in response to its inputs. Functional safety is achieved when every specified safety function is carried out and the level of performance required of each safety function is met.

Functional safety relies on active systems.

Safety achieved by measures that rely on passive systems is not functional safety.

Reactor

Basic Process Control System (BPCS)

Inputs Outputs

Safety Instrumented System (SIS)

Inputs Outputs

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Manufacturing:People and Machines

Production Cells / Centers

Reaction time 5 ...150msEN60204, IEC947-1,....NFPA 79, ISO 13849,....62061TÜV / UL / BG / BIA

Process Industry:People, Investments, Environment

Process Control

Reaction time 0.1 ...1sIEC 61.511,....

ISA 84

TÜV

ActuatorsSensors

Fail-safe Automation

movementsHazardous substances, pressure

Heating

Heat

Transportation

Materials

Functional Safety for Process versus Machinery

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Specifications 44.1%

Design &implementation

14.7%

Installation & startup5.9%

Operation & maintenance

14.7%

Changes after startup20.6%

Note : Based on 34 investigated incidents in the UKHealth and Safety Executive (GB): Out of Control. Why control systems go wrong and how to prevent failure. HSE Books 1995

Causes of Major Incidents Failure Analysis of Automatic Control Systems

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Failure causes

Personnel qualifications

Technical requirements

Safety management

+

+

LifecycleLifecycle

Specifications

Design & implementation

Changes after startup

Installation & startup

Operation & maintenance

Analysis

Robust Design

Robust Process

Addressing Failure Causes

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IEC 61508

IEC 62061 ISO 13849

EN 954(until 2009)

IEC 61511

Process

IndustryManufacturing Industry

Focu

sPr

oduc

t Man

ufac

ture

Focu

sIn

tegr

atio

n

Relevant good

practice

Harmonized

standards

Best practice for Functional Safety?

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Competence

What makes a person competent?:

Qualifications, experience and “appropriate qualities”

Training to ensure suitable knowledge of the standards / legislation / field / sector / products (Who?).Adequate knowledge of the hazards and failures of the equipment / process / system.Knowledge and understanding of working practices of organisation (work / contracted).Ability to communicate effectively with peers / staff / supervisors.Appreciation of their own limitations and constraintsWillingness to point out own limitations.

Competence Management Systems (CMS)

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Functional Safety Concept

Functional Safety

Control of dangerous failures during operation

robust design

Avoidance of systematicfailure in the concept, production and

operation of the systemsrobust process

Safety Lifecyle Requirement

Technical design requirements of safety-related functions

System Architecture

Failure Probability

Requirements of planning processes and methods

Functional Safety Management

From hazard/risk analysis through to decommissioning of SRS

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Management of Functional Safety

IEC 61511

Policy / StrategySafety Management SystemRoles / ResponsibilitiesRoles / CompetenceRisk Evaluation / ManagementSafety PlanningProcedures:

Implementation / MonitoringFunctional Safety AssessmentAuditing / RevisionConfiguration Management

IEC 62061

Safety Plan to include:Policy / StrategyApplication SoftwareRoles / ResponsibilitiesProcedures & Resources:

Hazard / Risk AssessmentEquipmentResponsible OrganisationAchieve / Maintain Func. Safety

Configuration ManagementVerification PlanValidation Plan

ISO 13849-1

DOES NOT MENTION FSMSoftware LIFECYCLEHazard / Risk – “Life Cycle”Annex G – Systematic Failure

Defined Validation Process:Basic safety principlesWell-tried componentsWell-tried safety principlesDefined rules for software

Measures for the control of systematic failuresMeasures for the avoidance of systematic failures

FSM = a good mechanism for demonstrating the implementation of:ISO 13849-1ISO 13849-2 (Validation)

Process Industry Manufacturing Industry Manufacturing Industry

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Example Safety Lifecycle - IEC 61511(ISA S84)

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Verification and Validation

Verification (in general) =“Are you making it right?"Verification is the process used to evaluate whether or not a system complies with regulations / specifications / conditions imposed at the start of a phase.

Validation (in general) ="Are you making the right thing?“Validation is the process of establishing evidence (including functional testing) that provides a high degree of assurance that a system accomplishes its intended requirements (Fit for purpose).

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Documentation for Functional Safety

Document everything!

EHSRHazard identificationRisk assessment & risk reductionVerificationValidationTechnical FileTechnical Construction FileCompetence Management SystemOperating ProceduresMaintenance / Isolation ProceduresEmergency ProceduresInspections / Metrics / Audits / Reviews

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Is it a common approach?

Commitment to SafetyCultureComplianceCompetence

Risk AssessmentKnowledge managementHazard Identification & risk assessment

Managing RiskOperating procedures / Safe working practicesAsset integrity managementEmergency management

Learning from ExperienceAccidents & near missesMeasurement metrics, audit & review

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Past & Present - Siemens & Safety

Extensive experience in functional safety for both Machine and Process sectors.

Currently:Market leader in Machine Safety Fastest growing in Process Safety

We have the products:Largest Portfolio of Safety ProductsExpertise in IEC 61508

We can deliver safety projects:Through competent partnersIn-house

We can provide safety services

Accident prevention must not be

regarded as the rule of law, but rather

as a dictate of human commitment and

economic rationality

(Werner von Siemens in the year 1880)

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Siemens Safety Product Offerings

IEC 61511 IEC 62061 ISO 13849-1Process Industry Manufacturing Industry Manufacturing Industry

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Siemens Safety Product Offerings

Detecting Reacting

SIRIUS contactorsSIRIUS motor startersSIRIUS compact feederSIMOCODESINAMICS G120 / G120DSINAMICS G130 / G150SINAMICS S110SINAMICS S120SINAMICS S150SINAMICS GM150/SM150SITRANS PS2 positioner

SIRIUS position switchesSIRIUS signal columnsSIRIUS EMERGENCY STOP SIRIUS speed monitors ASIsafe safe modulesSIMATIC Panel 277F IWLANSITRANS PSITRANS TSITRANS LROXYMAT 6 / ULTRAMAT 6

Evaluating

SIRIUS safety relaysSINAMICS ( )SIRIUS MSSASIsafeSIMATIC S7-300SIMATIC S7-400SIMATIC PCS7SIMATIC ET200

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Siemens’ Integrated Approach to Safety

Deep expertise in developing safety certified productsLargest portfolio of IEC 61508 safety-certified productsSafety and high-availability products integrated into machine automation and process automation systems

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Functional Safety Services

IEC 61511

Management and assessment of functional safety and auditsSafety planningHazard and risk assessment (HAZID / HAZOP)Allocations of safety functions to protection layersSIL assessments (risk graph, LOPA)Safety requirement specificationsAssessment of safety-related application codeVerification & ValidationModificationTraining

IEC 62061

Management and assessment of functional safetySafety planningHazard and risk assessment (ISO 12100)SIL assessmentsSafety requirement specificationsAssessment of safety-related application codeVerification & ValidationModificationTraining

ISO 13849-1

Management and assessment of functional safetySafety planningHazard and risk assessment (ISO 12100)PL assessmentsSafety requirement specificationsAssessment of safety-related application codeVerification & ValidationModificationTraining

Process Industry Manufacturing Industry Manufacturing Industry

Protection notice / Copyright notice

Pete BrownFunctional Safety SpecialistCustomer ServicesSiemens Industry

Ian CurtisProcess Safety Systems ConsultantIndustry AutomationSiemens Industry

Thank you for your attention!