Introduction of Speaker

Paul Gruhn, PE CFSE

Safety Systems Specialist for > 18 years

Process Solutions
User Group Meeting

ISA Fellow
Member of ISA SP84 committee
Instructor for ISAs web, 1, 3 & 5 day courses on
Safety Instrumented Systems

Trends in Process Safety

& Critical Control

Co-author of ISA book on Safety Instrumented

Systems

Paul Gruhn, PE, CFSE

ICS Triplex

Developer of commercial modeling software

Registered Professional Engineer in Texas
Certified Functional Safety Expert
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6th Annual Process Solutions User Group Meeting

6th Annual Process Solutions User Group Meeting

Question:

Question:

Would you rather learn from the mistakes of others, or make

them all yourself?
How many of you walk your dog without a leash?
1.
2.
3.
4.

Who me? I dont even own a dog!

Always
Sometimes
Never

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Why Should I Care?

Key take away

After Three Mile Island, but before

Chernobyl, the head of the Soviet
Academy of Sciences said,

It should not be necessary for each

generation to rediscover principles of
process safety which the generation before
discovered. We must learn from the
experience of others rather than learn the
hard way. We must pass on to the next
generation a record of what we have
learned. Jesse C. Ducommun

6th Annual Process Solutions User Group Meeting

Soviet reactors will soon be so safe that

they could be installed in Red Square.
Do you think hed say that now?

6th Annual Process Solutions User Group Meeting

Why Should I Care?

Why Should I Care?

After the Valdez tanker accident, the head
of the Alaskan Coast Guard said,

When the Bhopal plant manager was

informed of the accident, he actually said
in disbelief,

Thats impossible! We have the perfect

navigation system!

The gas leak just cant be from my

plant. The plant is shut down. Our
technology just cant go wrong. We
just cant have leaks.

6th Annual Process Solutions User Group Meeting

Overconfidence and complacency are

dangerous attitudes!

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Accidents & Resulting Regulations

Control System Incidents

Flixborough (UK)

What do you think is the leading factor in the cause of control

and safety system accidents?

1974: Safety case requirements in UK

Seveso (Italy)

1.
2.
3.
4.
5.

1976: Safety case requirements in Europe

Bhopal (India)

1984: Formation of AIChE CCPS

Piper Alpha (UK)

1988: Safety case requirements offshore

Incorrect / incomplete specs

Design / implementation errors
Installation errors
Changes after commissioning
Operations / maintenance errors

Pasadena (US)

1989: OSHA PSM

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Texas City (US)

1995: Regulations being proposed

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Guidelines, Standards & Regulations

Control System Incidents

Changes After
Commissioning 20%

UK HSE, Programmable Electronic Systems in Safety

Related Applications, 1987

Specification 44%

AIChE CCPS; Guidelines for Safe Automation of

Chemical Processes, 1993
ANSI/ISA 84; Application of Safety Instrumented
Systems for the Process Industries, 1996 & 2004

Operations &
Maintenance 15%
Installation &
Commissioning 6%

IEC 61508 (and 61511); Functional Safety - Safety

Related Systems, 1999

Design & Implementation

15%

OSHA CFR 1910.119; Process Safety Management

of Highly Hazardous Chemicals, 1992

From Out Of Control

A compilation of incidents involving control and safety systems by the UK HSE

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Safety Instrumented System

The Grandfather Clause

A system composed of sensors, logic solvers, and final control

elements for the purpose of taking the process to a safe state when
pre-determined conditions are violated.

PT
1A

Safety Instrumented
System (SIS)

Basic Process Control

System (BPCS)

Inputs

Inputs

Outputs

What is it?
What does it mean?
How do I interpret it?

Outputs

PT
1B
I/P

FT

Reactor

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Clause 1.y:

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Two Required Steps

For existing SIS designed and constructed in
accordance with codes, standards, or
practices prior to the issue of this standard
(e.g., ANSI/ISA-84.01-1996), the
owner/operator shall determine that the
equipment is designed, maintained,
inspected, tested, and operating in a safe
manner.

6th Annual Process Solutions User Group Meeting

Determine the SIL for each SIF

Determine whether existing SIFs meet
the required SIL
Other issues:
Have there been prior problems?
Audit your practices
Are the safety systems separate

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General Safety System Trends

Critical Process Control

Large economic and/or safety concerns

Smaller, distributed systems

Downtime
Capital
Image / reputation

Not all systems are 1,000+ I/O!

Field busses
FF, Profisafe, AS-Interface, HART

Applications:

Integrated control and safety

Total solution from one supplier

Field device diagnostics

Certified field devices
Partial stroking of valves

Personnel with certifications

Nuclear fuel rod control

Nuclear waste disposal
Space launch support facilities control
Turbomachinery (TMC)
Catalytic cracking control

TMR systems often viewed as the solution

CFSE/CSFP, FSExp, FSEng

ISA developing a program

High availability
Fault tolerant
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Final Thoughts

ICS Triplex & Industry Trends

Engineering, Integration & Technical Services

Engineering responsibility should not

require the stimulation that comes in the
wake of catastrophe
S.C. Florman

Training, SIL Determination,

SIL Verification & Facilitation

Conceptual Phase

Design Phase

Operation Phase

Conceptual
Process
Review

Perform
Hazard
Analysis & Risk
Assessment

Apply non-SIS
protection
layers to
prevent hazard

Define Target
SIL

SIS Installation,
commissioning
& pre-startup
accept.Test

Develop safety
Requirement
Specification
SIL Verification

Pre-startup
safety review

SIS Conceptual
Design
According to
SRS

Start-up,
operation,
maintenance &
periodic testing

SIS Detailed
Design

SIS
Management of
Change

SIS
Required?

Project Engineering

The result of the increased application of

hazard analysis has been a 50% reduction
in injuries, increased ease of operations,
and decreased production stoppages

Single, dual & triplicated systems; small to large

N. Leveson

Accidents are not due to lack of knowledge,

but failure to use the knowledge we have
System Assembly
and Staging

System Test

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T. Kletz

Maintenance
Contracts

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Safety The Easy Way!

Final Thoughts
When a mans education is finished,
he is finished

Hey, now wait a minute !

E.A. Filene

Do what the French did 200 years ago...

They passed a law requiring an
explosives manufacturer to
live on the premises...
with his family!

Those who cannot remember the past,

are condemned to repeat it
G. Santayana

Ignoring the problem wont make it go away

Anonymous

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Questions?

Paul Gruhn, PE, CFSE

Training Manager
paulg@icshou.com

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