Products Solutions Services. Functional Safety. How to determine a Safety integrity Level (SIL 1,2 or 3)

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1 Products Solutions Services Functional Safety How to determine a Safety integrity Level (SIL 1,2 or 3) Slide 1

2 Functional Safety Facts Agenda of the next 45 min SIL 1,2 or 3 Let s apply IEC61511 SIS, whats next?? How do I meet the SIL level? Slide 2

3 Functional Safety Facts What is functional safety? A safety instrumented system is 100% functionally safe if all random, common cause and systematic failures do not lead to malfunctioning of the safety system and do not result in Injury or death of humans Spills to the environment Loss of equipment or production 100% functional safety does not exist, but risk reduction SIL 1, 2, 3 or 4 does. Slide 3

4 Functional Safety Facts From Risk to Safety Risk R = P S Risk reduction Reduction of P Safety Risk reduction to a tolerable level. P = Probability of occurrence for a hazardous event, S = Extent of damage Slide 4

5 Functional Safety Facts Is there absolute safety? Initial risk Risk Risk without protective measures Risk reduction Structural measures Distribution of hazard Evacuation plans Mechanic, pneumatic Safety-related systems Tolerable risk Residual risk Slide 5

6 Products Solutions Services Safety Instrumented Systems Plant and Emergency Response Emergency response layer Mitigate Containment, Dike/Vessel Passive protection layer Relief valve, Rupture disk Active protection layer Prevent Safety Instrumented System Operator Intervention Emergency Shut Down Process Shutdown Safety layer Trip level alarm Process control layer Basic Process System Process Value Normal behavior Process alarm Process control layer Slide 6

7 Functional Safety Facts How to determine the required SIL? Risk Graph Risk Graph example Hazard SIL 3 4* 4 * single system not sufficient Slide 7

8 Functional Safety Facts Lets engineer our own Application Start: Store 30000l of Toluol as basic for the important intermediate product Toluol-2,4-diisocyanat (TDI) for Poly Urethane production. Easy inflame able Harmful to health Toluol tank burned in Germany, 2014 Target: Prevent vessel from bursting and avoid loss of liquid into the environment Slide 8

9 Functional Safety Facts SIF, safety function, SIL capability, SIL Safety Instrumented Function (SIF) Sensor Logic unit Actuator Subsystem Subsystem Subsystem Safety function(s) (e.g. MIN, MAX, pressure range) SIL capability (e.g. SIL 3) Safety function(s) SIL capability (e.g. SIL 3) Safety function(s) SIL capability (e.g. SIL 2) Safety function (e.g. max. pressure monitoring), SIL (e.g. SIL 2) Slide 9

10 Simply reliable: Process safety from Endress+ Hauser Single Channel System Example: single channel overfill prevention Sensor Logic Actuator SIL 2 PFDav= 0,35x10-2 SIL 3 PFDav=0,05x10-2 SIL 2 PFDav=0,4x10-2 Design rules SIL S, SIL L, SIL A SIL system PFD S +PFD L +PFD A < 10 -SIL system Sensor Logic Actor System SIL PFD av 0,3x10-2 0,05x10-2 0,4x10-2 0,705 x 10-2 System = SIL 2 Slide 10 Ngo

11 Simply reliable: Process safety from Endress+ Hauser Architecture of Multi-Channel Systems Safety 1oo4 Fundamental Safety Parameters PFDav HFT SFF for the complete system must be evaluated (e.g. Markov Model) 1oo3 2oo3 Which multi-channel system is safer than 2oo3? 1oo1 2oo2 3oo3 4oo4 Availability Slide 11 Ngo

12 Simply reliable: Process safety from Endress+ Hauser Approximation formula (Source: VDI/VDE 2180, Sheet 4) Options of Circuit Approximation formula for PFD av 1oo1 1oo3 1oo4 PFD 2 1 PFD DUT 1oo1 DUT 3 3 This is simplified. T 1 2 DUT 2 DU 1 DUT1 PFD1 oo3 Use MARKOV method 4to calculate 2 4 DUT1 DUT1 the PFD more PFD1 oo4 accurate oo2 PFD 2oo2 DUT1 2oo3 2oo4 PFD PFD 2oo3 2oo4 DU DU T 1 T DUT 2 1 DUT 2 1 DU = dangerous undetected, = Common cause Factor, T 1 = Time interval for proof testing [h] (1 Jahr = h) Slide 12 Ngo

13 Simply reliable: Process safety from Endress+ Hauser Complex calculation example(1) Target: SIL 2 Subsystem Sensor Subsystem Logic Unit Subsystem Actuator Sensor 1 Interface 1 Sensor 2 Interface 2 Sensor 3 Interface 3 2oo3 Module 1 Module 2 2oo2 Interface 4 Interface 5 Actu. 1 Actu. 2 l DU = 500 FIT (per line) b=10%, T 1 =1 year, SFF= l DU = 50 FIT (per Module) b=2%, T 1 =1 year, SFF= l DU = 1200 FIT (per line) b=10%, T 1 =1 year, SFF= Formula for für 2oo3 Formula for für Formula for für 2oo2 PFD av (S) = 2, PFD av (LE) = 4, PFD av (A) = 1, Result: PFD av (System) = PFD av (S) + PFD av (LE) + PFD av (A) = 1, SIL 1 FIT Slide = 13 Failures In Time, 1 FIT = Ngo /h Target not achieved! What to do?

14 Simply reliable: Process safety from Endress+ Hauser Complex calculation example(2) Action 1: Reduce Proof-Test Intervall from 1 year to ½ year Additional Cost! Subsystem Sensor Subsystem Logic Unit Subsystem Actuator Sensor 1 Interface 1 Sensor 2 Interface 2 Sensor 3 Interface 3 2oo3 Module 1 Module 2 2oo2 Interface 4 Interface 5 Actu. 1 Actu. 2 l DU = 500 FIT (per line) b=10%, T 1 =½ year, SFF= l DU = 50 FIT (per Module) b=2%, T 1 =½ year, SFF= l DU = 1200 FIT (per line) b=10%, T 1 =½ year, SFF= Formula for 2oo3 Formula for Formula for 2oo2 PFD av (S) = 1, PFD av (LE) = 2, PFD av (A) = 5, Result: PFD av (System) = PFD av (S) + PFD av (LE) + PFD av (A) = 5, SIL 2 Slide 14 Ngo

15 Simply reliable: Process safety from Endress+ Hauser Complex calculation example(3) Action 2: more redundancy (here: Actuator) additional costs! Subsystem Sensor Subsystem Logic Unit Subsystem Actuator Sensor 1 Interface 1 Sensor 2 Interface 2 Sensor 3 Interface 3 2oo3 Module 1 Module 2 2oo2 Interface 4 Interface 5 Interface 6 Interface 7 Actu. 1 Actu. 2 Actu. 3 Actu. 4 l DU = 500 FIT (per line) b=10%, T 1 =1 year, SFF= l DU = 50 FIT (per Module) b=2%, T 1 =1 year, SFF= l DU = 1200 FIT (per line) b=10%, T 1 =1 year, SFF= Formula for 2oo3 Formula for für Formula for /2oo2 PFD av (S) = 2, PFD av (LE) = 4, PFD av (A) 1, Result: PFD av (System) = PFD av (S) + PFD av (LE) + PFD av (A) 1, Slide 15 Ngo SIL 2

16 Simply reliable: Process safety from Endress+ Hauser Complex calculation example(4) Action: Correct selection of components from the beginning (here: Actuator) Subsystem Sensor Subsystem Logic Unit Subsystem Actuator Sensor 1 Interface 1 Sensor 2 Interface 2 Sensor 3 Interface 3 2oo3 Module 1 Module 2 2oo2 Interface 4 Interface 5 Actu. 1 Actu. 2 l DU = 500 FIT (per line) b=10%, T 1 =1 year, SFF= l DU = 50 FIT (per Module) b=2%, T 1 =1 year, SFF= l DU = 800 FIT (per line) b=10%, T 1 =1 year, SFF= Formula for 2oo3 Formula for Formula for 2oo2 PFD av (S) = 2, PFD av (LE) = 4, PFD av (A) = 7, Result: PFD av (System) = PFD av (S) + PFD av (LE) + PFD av (A) = 7, SIL 2 Slide 16 Ngo

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