Process engineering is the core engineering subject that deals with the industrial process. This specialized and advanced course on safety Instrumentation systems for process industries contains detailed technical ideas and concepts that are specially designed to improve the safety systems in process industries such as petrochemical industries, mineral processing, food processing, pharmaceutical industries and bio industries.
This detailed course with wide scope deals with the study and principles of safety instrumentation systems and their advancements. The overview of the safety instrumented systems with risk reduction methods, study and analysis on hazards, safety requirements, integrity systems, selection criteria of the instruments, design of various instruments, operation by manual and automation using safety controllers and the diagnostic methods for failure are discussed. The computer programming with practical issues has also been discussed.
The course is suitable for the technical professionals who are willing to enhance comprehensive technical as well as practical knowledge on instrumentation, process and automation systems. It is designed in such a way to develop the learners to gain knowledge on safety instrumentation systems and its advancements. In addition to the technical concepts, the system analysis by HAZOP and SIS analyses also discussed.
WHO SHOULD COMPLETE THIS COURSE
- Instrumentation engineers
- Process engineers
- Design technicians
- Consulting Engineers
- Engineering managers
- Project Engineer
COURSE OUTLINE
FUNDAMENTAL OF SAFETY CONTROL
- Scope, objective, principles , functional safety, failure
- Process control vs safety control
- Separation of safety controls from process controls
- Scope of a safety instrumented system
- Terminology
- SIF reliability block diagram
RISK REDUCTION AND RISK MANAGEMENT
- Risk reduction by action of the SIS
- Fault tree model
- Risk reduction for safety integrity levels
- Design principles
- Risk reduction factor
PROTECTION AND MANAGING RISK
- Layers of protection
- Purpose
- Typical structure of health and safety regulations for industry
- Seveso ii and comah regulations
- Legal framework for tolerable risk
- Risk matrix
STANDARDS FOR SAFETY SYSTEMS
- IEC standards for functional safety
- New standards linked to IEC 61508 and IEC 61511
- Safety integrity levels: system design errors dominate failures of safety systems
- Setting the SIL targets
- Quantitative method for SIL determination,
- Safety instrumented systems: potential failure of the SIS
SAFETY ON PLC
- Single channel safety PLC architecture with diagnostics
- Characteristics of a safety PLC
- Management of functional safety
SAFETY LIFE CYCLE IN IEC 61511
- Fundamentals of safety life cycle : principles, progression
- IEC 61511 safety life cycle phases
- Safety allocations procedure
- Safety requirement specifications
- Commissioning and validation stages
- Operation & maintenance
- Modification and decommissioning
FUNDAMENTALS OF HAZARD STUDIES
- 6 level hazard study lifecycle
- Level 2 or PHA stage – systematic procedure
- Finding causes of hazardous events
- Mapping of hazard studies into risk reduction
- HAZOP
- Methodology
- Concept of change paths
- Examples of a deviation test
- HAZOP worksheet record
ANALYSIS OF HAZARD
- Evaluating plant risks
- Batch processes
- Hazard analysis by fault tree methods
- PRINCIPLES OF SAFETY
- Safety allocations phase of the safety life cycle
- Road map for Hazard
- Layers of protection
- Independent protection layers
- BPCS as risk reduction layer
RISK REDUCTION MODELING I-II
- Typical process alarms
- Minimal safeguards, safety related alarm with independent sensor and display
- Risk reduction model for boiler level example
- High level hazard problem
- Fault tree and hazard analysis for tank example
- Risk reduction model for the protected hazard
SAFETY REQUIREMENTS SPECIFICATION
- General structure
- Safety integrity specification
- Safety instrumented function
- Cause and effect diagram
- Trip logic diagram version of the matrix
- New method for the SRS: IEC 61508
- Decision using risk matrix
SIL DETERMINATION METHODS
- SIL determination methods for SRS
- Overview of IEC 6151 part 3
- ALARP concepts and procedure
- Safety Integrity levels
- Principle of quantitative methods for SIL determination
- Event tree analysis method for hazard with SIL 2 protection
SIL - SAFETY LAYER MATRIX
- SIL classification by safety layer matrix diagram
- SLM and Risk chart – boiler example
- Consequence parameters and summary of Risk Graph
LAYER OF PROTECTION ANALYSIS (LOPA)
- Buffer storage tank example with procedures
DESIGNING THE SIS TO MEET THE SIL TARGET
- Build SIL target using hardware
- Hardware parameters impact the SIL
- IEC 61511 rules and guidance
- Architecture and fault tolerance concepts
- Instrument system failure
- Safe failure fraction
- SFF calculation
ARCHITECTURES FOR SAFETY SYSTEMS
- SIS architecture
- Design steps for the sensor and actuator sub systems
- Single channel subsystems
- Architecture rules for PES logic solvers
- Sequence for design steps
FUNDAMENTALS OF SIL INSTRUMENTS
- Requirement for instrument selection
- Impact on SIS reliability
- Types of sensors and actuators
- Failure modes and causes
SELECTION METHODS
- Separation, redundancy, diversity and diagnosis
ISSUES AND TECHNOLOGIES
- Device selection issues and safety documents
- Smart technologies
- Safety certified instruments and fieldbus
FUNDAMENTALS OF SIS
- Reasons and objectives
- Terminology
- Applications
- Design iteration for target PFD
SIS MODEL
- Resolving the SIS into reliability block diagrams identification of formulae
- Failure mode
- Trial calculation examples
SIS ANALYSIS
- Model example with stages explained in detail
- Calculation software tools
OVERVIEW OF SAFETY CONTROLLERS
- Logic solver duties
- Programmable Electronic systems development
- SIS architecture
- LOGIC solver development
- Relay based SIS with panel control
- Safety relays
- PLCs
- Issues in usage of safety applications
- Safety PLCs and models
- Characteristics of safety PLCs
- IEC 61511 for standard PLCs
SAFETY CONTROLLER TECHNOLOGY
- Fail safe communication
- Essential requirements for a safety critical network
- Functional safety
- Safety integrity
- Safety bus
- Shared bus system integrated control and safety
SYSTEM INTEGRATION
- Problem with software, SIS software basics
- Activity model for SIS development phases
- Software safety life cycle
- Benefits of limited variability languages
APPLICATION SOFTWARE FOR SAFETY CONTROLLERS
- Application software activities and steps up to FAT
- FAT and test simulation methods
- Software quality management
- Certification and compliance
DOCUMENTATION OF SAFETY SYSTEMS
- IEC 61511 specifies the documentation requirements
- Documentation schedule
- Information and documentation for SIS implementation
- Risk reduction diagram,
- Safety Requirements specification
- Development of SIF logic using flow charts
VERIFICATION AND VALIDATION
- SIL verification- architecture and reliability calculations sheet
- Validation vs verification
- IEC installation phases
FUNCTIONAL SAFETY ASSESSMENT
- Device functional checkout
- Safety validation and correction process
- Training essentials
- Maintenance Management Program: IEC 61508
- Maintenance management model
- Reasons for invoking an MOC procedure
PROOF TESTING OF SAFETY INSTRUMENTATION
- Introduction, purpose
- Untested SIF, Proof tested SIP, Diagnostic and proof tested SIF
- Effect of manual proof testing
- Effect and limitations
- Proof testing strategies
- Sensor testing methods
- Valve on-line testing methods
- Bypass valve to permit on-line proof testing
DIAGNOSTICS OF SAFETY INSTRUMENTATION
- Methods for valve diagnostics
- Key issue for the value diagnostics
- Failure parameters in partial stroke test
- Design example- SIL 2 single or double valve decision
- Management of functional safety IEC 61508 – 1
