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Safety Instrumented
Systems
SIS
And Safety
Integrity Level
SIL
Protecting
People,
Profitability
and Productivity
I
ndustrial safety in pre-digital eras centered mainly around safe
work practices, hazardous materials control, and the protective
“armoring” of personnel and equipment. Today, safety penetrates far
deeper into more complex manufacturing infrastructures, extending its
protective influence all the way to a company’s bottom line.
Contemporary safety systems reduce risk with operational advancements
that frequently improve productivity and profitability as well.
New Standards. Until the 1980s safety management was largely self-
A WWII-era safety poster regulated. Prompted by the ascendency of electronic control devices,
growing complexities in manufacturing systems, environmental protec-
tion mandates, and a greater need to protect plant assets, new interna-
tional safety standards have emerged and continue to evolve. With the
M I L E S T O N E introduction of standards such as IEC 61508, IEC 61511 and ISA 84,
TUV (Bavaria) Microcomputers in
interest in Safety Instrumented Systems (SIS) and general instrument
Safety-Related Systems (1984) reliability has grown. In the pages ahead we’ll describe the basics of SIS
and Safety Integrity Level (SIL). We’ll conclude with an overview of
Health & Safety Executive (UK) Magnetrol’s level and flow instrumentation products that are suitable for
Programmable Electronic Systems in
these new standards in safety and we’ll detail their reliability. Reliability
Safety Related Applications (1987)
is the key, for even non-safety related people are now using analysis data
OSHA (29 CFR 1910.119) (1992): from these new regulations as an insight into device performance.
Process Safety Management of
Highly Hazardous Chemicals Understanding Risk. All safety standards exist to reduce risk, which is
inherent wherever manufacturing or processing occurs. The goal of elim-
inating risk and bringing about a state of absolute safety is not attain-
Instrument Society of America
ANSI/ISA 84 (2004):
Safety Instrumented Systems for
able. More realistically, risk can be categorized as being either negligible,
the Process Industries tolerable or unacceptable. The foundation for any modern safety system,
then, is to reduce risk to an acceptable or tolerable level. In this context,
International Electrotechnical safety can be defined as “freedom from unacceptable risk.”
Commission (1998-2003) The formula for risk is:
IEC 61508 (2000): A general
approach to Functional Safety Systems RISK = HAZARD FREQUENCY x HAZARD CONSEQUENCE
IEC 61511 (2003): Process sector
implementation of IEC 61508 Risk can be minimized initially by inherently safe process design, by the Basic
Process Control System (BPCS), and finally by a safety shutdown system.
3
process operations and the severity of its inherent risks, such an analysis
may range from a simplified screening to a rigorous Hazard and
Operability (HAZOP) engineering study reviewing process, electrical,
mechanical, safety, instrumental and managerial factors. Once risks and
hazards have been assessed, it can be determined whether they are below
acceptable levels. If the study concludes that existing protection is insuf-
ficient, a Safety Instrumented System (SIS) will be required.
4
Safety Instrumented
Systems (SIS)
The Safety Instrumented System (SIS) plays
a vital role in providing a protective layer
around industrial process systems. Whether
called an SIS, emergency or safety shutdown
system, or a safety interlock, its purpose is to
take process to a “safe state” when pre-deter-
mined set points have been exceeded or when
safe operating conditions have been trans-
gressed. A SIS is comprised of safety functions
(see SIF below) with sensors, logic solvers and
actuators. Figure B shows its basic components:
• Sensors for signal input and power
• Input signal interfacing and processing
• Logic solver with power and communications
• Output signal processing, interfacing and power
Figure B Process schematic
SIF 1 SIF 2 Like the safety features on an automobile, a SIF may operate continu-
SIL 2 SIL 2 ously like a car’s steering, or intermittently like a car’s air bag. A safety
function operating in the demand mode is only performed when
required in order to transfer the Equipment Under Control (EUC) into a
SIF 3 specified state. A safety function operating in continuous mode operates
to retain the EUC within its safe state. Figure C shows the relationship
SIL 2
between SIS, the Safety Instrumented Functions it implements, and the
Safety Integrity Level that’s assigned to each Safety Instrumented
Function.
Figure C Every SIS has one or
more safety functions (SIFs) and
fied. The safety life cycle shows a systematic approach for the develop-
assigned SIL. Process controls
are “suitable for use” within a
given SIL environment. ment of a SIS. A simplified version is shown in Figure D.
5
4 >99.99% 10-5 to <10-4 100,000 to 10,000 Potential for fatalities in the community
Figure E 3 99.9% 10-4 to <10-3 10,000 to 1,000 Potential for multiple fatalities
SIL and
2 99-99.9% 10-3 to <10-2 1,000 to 100 Potential for major injuries or one fatality
Related
Measures* 1 90-99% 10-2 to <10-1 100 to 10 Potential for minor injuries
AVAILABILITY: The probability Analysis (FMEDA) is a detailed performance evaluation that estimates the fail-
ure rates, failure modes, and diagnostic capability of a device.
that equipment will perform its
task.
PFDavg: The average PFD used The following concepts define key FMEDA data for SIL-suitable Magnetrol
in calculating safety system controls shown on pages 7 to 10:
reliability. (PFD: Probability of
• FITS. Column one shows failure rates are shown as Failures in Time
Failure on Demand is the
(FITs) where 1 FIT = 1 x 10-9 failures per hour. A second failure rate column
probability of a system failing
to respond to a demand for
action arising from a potentially has been added showing Annual data as it is becoming a commonly used
value.
hazardous condition.)
• SERIES. The brand and model designation of the control, e.g. Eclipse® 705.
• SIL. A device’s Safety Integrity Level per IEC 61511. Because combined
* Both IEC and ANSI/ISA
standards utilize similar tables
covering the same range of sensors can increase the SIL, it is often stated as “1 as 1oo1 /2 as 1oo2,”
PFD values. ANSI/ISA, how-
meaning: SIL 1 if the device is one-out-of-one used; SIL 2 if it is one-out-of-two
devices used.
ever, does not show a SIL 4.
No standard process controls
• SFF. Safe Failure Fraction indicates all safe and dangerous detected
failures. The formula for determining SFF is: The total failures minus the
dangerous undetected failures divided by the total failures. A SFF of 91%
FINAL WORD for the Eclipse 705-51A, for example, means that 91% of the possible failures
are self-identified by the device or are safe and have no effect.
• Eclipse® Guided Wave Radar Eclipse Model 705 (510) Model 705 (51A)
Level Transmitter
SIL 1 as 1oo1 2 as 1oo1
The Eclipse guided wave radar level
Instrument Type B B
transmitter is the latest generation of
SFF 84.5% 91.0%
loop-powered 24 VDC transmitters.
PFDavg 8.06E-04 4.69E-04
Eclipse interchanges with coaxial,
twin rod, and single rod probes. A
FITS Annual FITS Annual
PACTware™ DTM interface offers the
Fail Dangerous
leading-edge in configuration, diag-
Undetected 183 1.60E-03 106 9.29E-04
nostics and graphics.
Fail Dangerous
Detected 567 4.97E-03 650 5.69E-03
SIL-Suitable Controls
LEVEL and FLOW SWITCHES CONTINUED
Subject: www:
IEC standards & bookstore................................iec.ch/home
ISA standards & bookstore................................isa.org
Exida engineering guides...................................exida.com
TUV functional safety services...........................tuv-global.com
UK Health & Safety Executive............................hse.gov.uk
Institution of Chemical Engineers...................... icheme.org
IHS/Global engineering documents...................global.ihs.com
Factory Mutual process safety...........................fm global.com
OSHA process safety standards........................osha.gov
Center for Chemical Process Safety..................aiche.org
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