Safety Instrumented Systems Training Course

• Differentiate between process control and safety control
• Implement the ISA84 standard
• Evaluate process risk levels
• Calculate and determine Safety Integrity Levels (SILs) using a variety of techniques
• Analyse the performance of different logic system technologies
• Examine the performance of the various sensor, logic, and final element

Introductions
• Managing Risk in Oil and Gas Timeline of Disasters and Standards
• What Is a Safety Instrumented System?
• Confusion in the Industry Technology Choices, Redundancy Choices, Field Devices and Test Intervals
• Industry Standards, Regulations, Recommendations, Guidelines and HSE – PES
• Generic and Application Sector Standards
• Safety Instrumented System Standards: IEC 61508. ANSI/ISA-84.00.01, IEC 61511, NFPA 85, API RP 556, API RP 14C, OSHA
• Design Lifecycle-Findings of the HSE
• Hazard & Risk Analysis
• SIS Design & Engineering
SIS-Safety Instrumented Systems
• What is SIF (IPF)?
• What is a Safety Instrumented System (SIS)?
• SIS Safety Lifecycle
• Lifecycle Graphic
HAZOP & LOPA
• SIS Safety Lifecycle – Hazard Identification
• Defining a Hazard
• The HAZOP Process
• GP 48-02 HAZOP process – simplified
• Consequence Severity and Likelihood – Determining Risk Ranking
• Risk Matrix and example
• Safety criteria, Environmental criteria, Commercial criteria
• Tolerable Risk
HAZOP & SILs
• SIL Determination
• Layers of Protection Analysis (LOPA):
• IEC 61508 / IEC 61511 – Risk graph
• Fault Trees, Safety Integrity Levels (SIL)
Layers of Protection & LOPA
• Layers of Protection – The Swiss Cheese Model
• Layers of Protection Analysis (LOPA)
• LOPA – Steps (provided for reference)
• Another model to look at how LoPs mitigate risk to the tolerable level – Over-pressure example
• LOPA – How much credit for LoPs?
• Applying LoPs to reduce risk
• LOPA – Participant requirements
• Process industry LoP Example – Simple vessel, Simple vessel/reactor
• Requirements for Layers of Protection – Four Further Criteria
• LOPA example – multiple causes
• HAZOP vs. SIL
Basic Process Control System (BPCS) Layers of Protection
• Instrument Layers of Protection are in Various Systems
• Operating Limits
• BPCS Layers of Protection – 1. Control Loop, 2. Safety Related Alarm (SRA), 3. BPCS Interlock Function
• Other requirements for BPCS LoPs – Independence, Identification on HMI graphics
• Identification of Control Loop & SRA on the HMI graphics – Examples
• Let’s take a closer look at Alarm Requirements
• Critical Fault Alarms
• Identification of SRA’s in the Alarm
• Safety Related Alarm Register
Understanding Failures
• The Swiss Cheese Model – Understanding Failure Representation and Impact
• Understanding Failure – Example of a PC and a Transmitter
• Types of Failures – Random Hardware Failures and Failures due to Human Errors
• Effect of a Failure – Safe and Dangerous Failures
• Safe and Dangerous Failures – Examples
• Failure Modes – Detected or Undetected
• Four Failure Modes
• Example of an Undetected Failure
• Common Cause and Common Mode Failures
• Avoiding Common Cause Failures in Operations and Maintenance
• Exercise – A potential failure
Human Error
• Human error – Consider a simple task which we do very often
• The Level of Human Error
• Human Error – The Basics
• The normalisation of Deviance – Exercise
• Human Error and the SIS Safety Lifecycle
• Human Error in Hazard Identification and Layer of Protection Definition – Examples (for Reference), Detailed Engineering and Assembly – Examples (for Reference), Installation, Commissioning and Validation – Examples (for Reference), Operation and Maintenance – Examples (for Reference), Modification or Decommissioning – Examples (for Reference)
• Human Error related to SIS Safety Lifecycle Management – Examples (for Reference)
• Avoiding Human Errors – What can we do?
• An Example – Avoiding Human Error
• Safety Culture
Safety Integrity Level (SIL) Categorization and Safety Integrity
• HAZOP vs. SIL
• SIL Determination
• Probability and likelihood of Failure on Demand and Risk Reduction
• PFD calculation for Safety Instrumented Function
• Safety Integrity Level
• Safety Integrity Level Categorisation
• Environmental and Commercial Integrity Levels
• Other Integrity Level functions – SIL 0 and no SIL rating
• Hardware Selection, Reliability, Fault Tolerance and Failure Robustness
• Fault-Tolerant Architecture – 1oo2, Failure Robust Architecture – 2oo2, Architecture Resilience – 2oo3 Inputs and 1oo2 Outputs
• Summary of Architecture – Advantages & Disadvantages
• Probability of Failure and Purpose of Proof Testing
• Proof Testing Impact of PFD
Override Control
• Override Definition, Exercise – Bypasses, Examples of Overrides
• A typical facility and its protection
• All layers of protection in place
• Fire and Gas Detection taken out for maintenance
• Temporary mitigation put in place
• Implications of Overrides
• Override Procedure – Typical ‘Best Practice’ Workflow
• Override-Equivalent Compensating Measures
• Safety Override Considerations
• Safety Override and Risk Assessment – SORA
• Generation of a SORA
• Reusing SORAs
• Override Key Performance Indicators (KPIs)
• Override Decision Tree
Operations Role in the SIS Safety Lifecycle/Operations Role in Maintaining LoP Integrity
• Operators Role in the SIS Safety Lifecycle
• Exercise – Control Loop credited in LOPA
• Control Loop credited in LOPA – Manual mode
• Control Loop credited in LOPA – Setpoint adjustment
• Control Loop credited in LOPA – Hardware Failures
• Control Loop credited in LOPA – Poor Loop Performance
• Exercise – Safety Related Alarms
• Safety Instrumented Functions – Proof Testing
• Safety Instrumented Functions – Minimizing Human errors
• BPCS Interlocks
Demand Tracking/Maintenance Role in the SIS Safety Lifecycle/LoP Maintenance & Proof Testing
• What is a “Demand”?
• A simple LoP example
• What creates Demands on an LoP?
• Which Demands to Track?
• Benefits of Demand Tracking
• How to Track Demands?
• Safe Operating Limits and Demand Tracking
• Maintenance Role in Safety Lifecycle
LoP Maintenance & Proof Testing
• Exercise – Routine Maintenance on a car
• Different types of maintenance
• General Maintenance – Exercise
• Routine Maintenance Planning
• Proof Test Coverage – Proof Test Coverage from various Means of Testing on the SIS Input
• Inspection Tasks
• Proof Testing impact of PFD
• Partial Stroke Testing
• Proof Testing – Definition, Example Analogy – Why do we proof test?, Principles, End-to-End Testing, Continuously or in Parts, Online or Offline, A comparison of two variations of ‘End-to-End’ testing, Continuous vs. Testing-In-Parts
• Continuous and Testing-In-Parts – Advantages and Disadvantages
• Online & Offline Testing – Advantages
• Proof Testing – Inputs, Logic Solver, and Outputs
• Proof Testing – Data Captured
• Exercise – Does this valve “pass” on its proof test?
• Exercises and Summary

Methodology
The training methodology integrates lectures, interactive discussions, collaborative group exercises, and illustrative examples. Participants will acquire a blend of theoretical insights and hands-on practical experience, emphasizing the application of learned techniques. This approach ensures that attendees return to their professional environments equipped with both the competence and self-assurance to effectively implement the acquired skills in their responsibilities.

DATE:

1ST BATCH:        11th – 14th Mar, 2025   

2ND BATCH:       26th – 29th Aug, 2025