Functional safety application and nuance between O&G, Power Generation and heavy materials handling industries Hosted By: Engineered Safety David Hawkins 17 February 2014

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Introduction

What is to be presented

• Process Risk & Functional Safety

• Heavy Industry Features

• Power Generation Features

• Oil & Gas Features

• Synopsis

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Safety life cycle

Analysis

Realisation

Operations and maintenance

VerificationFunctional Safety

Management • Hazard identification • Risk analysis• Layer of protection

analysis• SIL selection

• HAZOP report • Safety Allocation Report• Safety Requirements

Specification• Functional

Safety Management Plan

• SIS design • Installation• Commissioning• Validation

• SIS schematics and documentation

• Safety calculations• Third party verification

report • FAT procedures and

records• Validation procedures

and records

• Periodic proof testing• Compliance audits• SIS modifications

• Operations and maintenance procedures

• Incident logs

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Risk assessment process

Project Development

Process and project definition

Project design

Procurement and construction

Commissioning

Operation

1

2

3

4

5

Stage 2 : Concept Approval

Stage 5: 12 months into operation **

Stage 1 : Early Concept

Stage 3 : 50 % to 80 % design

Stage 4 : Prior to service **

** : Check list method may be suitable

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Risk assessment process

Qualitative:Safety In DesignTop Down HAZOP

Semi-Quantitative:Bottom up HAZOPMachine Safety Risk Assessment

Quantitative:HAZOP (strict historical data & mathematical relationships)Consequence AnalysisLikelihood AnalysisEvent Tree AnalysisLayer of Protection AnalysisSafety Requirements Specification

Criteria i- Initial risk process for plant- Hazards can be mitigated to a broadly tolerable level without implementing instrumented controls- Criteria ii hazards passed to next phase

Criteria ii- Hazards tend to higher consequence- Machine Safety standard applies (AS 4024)- Instrumented controls required for safety- Materials and equipment selection impact on hazard- Hazardous chemicals, emissions or wastes- Criteria iii hazards passed to next phase

Criteria iii - Regulatory requirement for quantified assessment- Highly Hazardous Chemicals or Major Hazard Facility- Industrial and commercial gas-fired appliances AS (3814)- Pipelines-Gas and liquid petroleum (AS 2885)- Complex system noted in AS 4024- SIF in range of SIL 1 and SIL 3- Then AS IEC 61508 series applies- Special requirements apply to hazards exceeding criteria iii

AS 2067 Substations & HV installations – recommends risk assessment in regard to protection against fire and explosion

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Tolerable risk

PLL = probability of loss of life PI = probability of injury EV = Estimated Value

Also called ALARP region

Varies from site to site

Safety Everything else

AS 5577 – 2013 Electricity network safety management systems + many others

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Tolerable risk

IncreasingRisk

Likelihood

Consequence

Unacceptable Risk Region

Broadly Acceptable Risk Region

Inherent risk of the hazard

(ie No mitigation)

Non-SIS likelihood reduction - ILP(ie Relief valve)

Non-SIS consequence

reduction - ILP(ie Containment)

Risk after non-SIS mitigation

SIS risk reduction(SIL 1 -4)

Final risk after mitigation

ALARP Region

ILP = Independent Layer of Protection

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• AS4024 Machine Safety • AS 62061 Safety of machinery • ISO 13849 Performance Levels • Typically low occupancy

Heavy Industry Features

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• AS 61511 Functional safety – SIS for the process industry sector • Typically Turbo-generator and boiler protection, Burner and ignition

analysis, fire systems • Typically low likelihood high consequence

Power Generation Features

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• AS 3814 Industrial and commercial gas-fired appliances

• AS 61511 Functional safety – SIS for the process industry sector

• AS 2885 Pipelines - Gas and liquid petroleum - General requirements

• Typically low likelihood high consequence

• Typically most mature

Oil & Gas Features

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• Certified Functional Safety Expert

– www.cfse.org

– Standards require proof of qualification, to ensure safety knowledge and skills are up to date

– The CFSE program is the most stringent in the world and represents the best demonstration of competency in the world

• TUV Functional Safety Engineer

– www.hima.com.au

– The person has participated in the TÜV Functional Safety Program concerning IEC 61508 and successfully passed the final exam

– Has obtained the title "TÜV Functional Safety Engineer" within the TÜV Functional Safety Program

Competencies

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• Thankyou

• Questions

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