Safety Integrity Level

Trilok Jadhav
Functional Safety

• What is Safety?
– “Freedom from unacceptable risk”

• What is Risk?
– Combination of frequency of occurrence of harm & the
severity of that harm

• Requirement of Functional Safety

– Reduce risk to an acceptable level in process industry

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Safety System

• What is a safety system?

– It is an independent system that brings the process to a safe
state in case that process runs out of control.
– System must be independent of the risk it is protecting
against.
– Safety system and control system must be carefully
separated.
– Keep in mind that a normal control system may be the cause
of a hazardous situation
– Each must have their own set of transmitters and final
elements.
– e.g. TCPP & TPP PCS and ESD system and their instruments

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Why we need safety system ?

• 3800 died at that night

• 10000 since then
• Fine of $470 million

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Why we need safety system ?

• 167 died and many burnt

• About 13000 million GBP damage
• Occidental is no more in business

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Causes of Accident

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Process Risk

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Standard

• IEC 61508 – (1998-2000):

– Functional safety of electrical / electronic / programmable
electronic safety related system

• IEC 61511 – (2003):

– Functional safety for process industry
– Applicable for end users, contractor, system integrator & safety
system suppliers.
– There is special focus on the design & validation of safety
related systems.

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Standard characteristics

• Pipe to pipe approach

– Complete safety loop has to be taken into account.
– Loop normally comprises initiating devices, a logic solver and final elements.
– Purchasing a safety certified PLC is not enough to fulfill all the safety
requirement of the system
– e.g. pulse energized valves connected to PLC system
• Quantitative safety assessment:
– During hazard and risk analysis all potential hazards are indentified & classified.
– Result of these studies are defined Safety Instrumented Functions (SIF) &
the required risk reduction for each SIF.
– Risk reduction of each SIF are so called Safety Integrity Level (SIL) range
from 1 to 4

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Standard characteristics

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 Hazard and Risk Analysis
• Fundamental principle of the standards is that safety requirement are based on an analysis of
the risk posed by process installation.
• HAZOP:
– Hazardous and Operability study
– Intention is to identify potential hazards and to define the safety functions to protect against the hazard
– Output of HAZOP is a report in which all potential hazards are listed.
– Team consist of : Process designer, instrument, safety, electrical, mechanical engineers.
– Basis of HAZOP is formed by P&IDs, Cause & effect, plans etc
– Next step is to determine the safety Instrumented functions (SIF) & potential hazard related to
each SIF.
• Risk Assessment:
– Intention is to define the required risk reduction or SIL for each safety function.
– Starting point is the HAZOP report
– Again it requires a team as above.

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What are the SIFs?

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What are the SIFs?

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Determination of SIL?

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Determination of SIL?

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SIL?

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SIL?

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• In Practice for many installation about 80% of the real SIFs will be classified as
SIL1,
• About 15% will become SIL2
• About 5% will become SIL3
• Safety function that are rated SIL4 are very rare and should be avoided. It is
strongly advised to re-design the process to lower this requirement.
• It will be very difficult and costly to maintain a SIL4 safety function during the life
time of the plant.

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Risk Reduction

• Risk Reduction can be achieved in several ways;

– External risk reduction facilities
– Mechanical Safety devices
– Safety Instrumented system (SIS)

Consequences
Process Mechanical
External SIS
Risk
Frequency

Necessary risk reduction

Hazardous Event

Tolerable Risk
Target

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System Architecture

• HFT: “ Hardware Fault Tolerance”

– This means the safety system must still be able to do its job
when it contains one or more undetected failures.
• SFF: “Safe Failure Fraction”
– It is defined as the ratio of the safe failure rate plus detected
failure in functional unit to the total failure rate of that unit.
– It is determined by the supplier of the device during the
design of it.
– It signifies quality of instrument.

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Exercise # 1

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Exercise # 1

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Exercise # 2

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Exercise # 2

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Thank You