Last Updated S012019

MSR505

Unit Name SAFETY SYSTEMS – TOOLS AND METHODS
Unit Code MSR505
Unit Duration 1 Term (online) or 1 Semester (on-campus)
Award

Graduate Diploma of Engineering (Safety, Risk and Reliability)

Duration: 1 year

Master of Engineering (Safety, Risk and Reliability)

Duration: 2 years  

Year Level One
Unit Creator / Reviewer Mark Andrew | Keerthy Mysore
Core/Elective: Core
Pre/Co-requisites Nil
Credit Points

3

Grad Dip total course credit points = 24

(3 credits x 8 (units))

Masters total course credit points = 48

(12 credits (Thesis) + 3 credits x 12 (units))

Mode of Delivery

Online or on-campus.

Combination of modes: Online synchronous lectures; asynchronous discussion groups, videos, remote and cloud-based labs (simulations); web and video conferencing tutorials. High emphasis on personal and group self-study.  

Unit Workload

Total student workload including “contact hours” = 10 hours per week:

Lecture – 1 hour

Tutorial Lecture - 1 hour

Practical / Lab - 1 hour (if applicable)

Personal Study recommended - 7 hours

Unit Description and General Aims

This unit provides the fundament concept of functional safety systems to reduce the likelihood of a serious hazardous event in an industrial process plant. In this subject the student will be introduced to a common safety philosophy of hazard identification, risk management and risk based design of protection methods. A series of topics will prepare the student for a practical and challenging application project typical of those currently seen in large chemical processing plants. These aspects are addressed in this unit.

Learning Outcomes

On successful completion of this unit, students are expected to be able to:

1. Appreciate relevance of Hazardous area classification and electrical protection methods with reference to IEC 60079.

2. Appreciate how a safety control systems project is planned and executed in accordance with the safety life cycle requirements of internationally recognized standards IEC 61508 and IEC 61511.

3. Participate in and make a valuable contribution to any HAZOP study workshop.

4. Evaluate cost effective safety system solutions for hazardous processes and justify the investment to the operating company.

5. Develop training and competency growth programmes to enable a company to appreciate the functional safety management requirements of IEC 61508/61511.

Student assessment

Assessment Type

(e.g. Assignment - 2000 word essay (specify topic) Examination (specify length and format))

When assessed

(eg Week 5)

Weighting (% of total unit marks) Learning Outcomes Assessed

Assessment 1

Type: Quiz

Word length: n/a

Topic: IEC 60079, IEC 61508 and IEC 61511.   

Week 5 20% 1, 2

Assessment 2 - mid-semester test

Type: Report (Midterm Project)

[This will include a progress report; literature review, hypothesis, and methodology / conclusions] Word length: 1000

Topic: Standards and HAZOP in the workplace (with LOPA and basic SIS).   

Week 7 25% 1, 2, 3

Assessment 3

Type: Report (Final Project)

[If a continuation of the midterm, this should complete the report by adding sections on: methodology, implementation / evaluation, verification / validation, conclusion / challenges and recommendations / future work. If this is a new report, all headings from the midterm and the final reports must be included.]

Word length: 2000

Topic: Example hypothetical SIL and SIS project (integrity, validation and testing with examples for each). 

Week 12 35% 4, 5

Practical Participation     

Continuous 15%  5

Class Participation

 

Continuous 5% 1 - 5

 

Prescribed and Recommended readings

Required Textbook

 R. Garside, Electrical Apparatus and Hazardous Areas, 5th Edition, 2007.

 P. Gruhn and H. Cheddie, Safety Instrumented Systems: design analysis and justification, 2nd edition, ISA, Research Triangle Park NC, 2006

 

Reference Materials

  • Functional safety of electrical/electronic/programmable electronic safety-related systems, IEC standard 61508-1 to 7, 
  • Functional Safety - Safety instrumented systems for the process industry sector. Parts 1 and 3, IEC standard 61511, 2002. (OR AS 61511 or BS EN 61511 or ANSI/ISA S84.01:2004)
  • Hazard and Operability Studies (HAZOP studies) - Application Guide, 1st edition, Engineering guide IEC 61882, 2001-05.
  • Explosive Atmospheres Part 14: Terminologies and principles, IEC standard 60079-14, 2002.
  • F. Crawley, et al., HAZOP Guide to Best Practice, 2000.
  • T. Kletz, HAZOP and HAZAN, 4th edition, I Chem. Eng Rugby, UK, 1999.
  • IDC / EIT notes and Reference texts as advised. 
  • Other material advised during the lectures.

Unit Content

One topic is delivered per contact week.

 

Topic 1

Introduction to Safety Classifications

1. Safety management principles

2. Principles and classification of flammable atmospheres

3. Engineering standard IEC 60079 for hazardous atmosphere practices

 

Topic 2

Electrical Protection Methods

1. Protection methods including intrinsically safe field bus concepts

2. Maintenance and competency requirements for Ex systems

3. Risks of offshoring

Topic 3

HAZOP Study

1. Hazard identification in automated plants

2. Hazard and Operability Study (HAZOP) method

3. HAZOP leadership

4. Worksheet reporting using Excel and other database programs

5. Ways a HAZOP study can be executed and comply with IEC 61882 and not be worthwhile

6. Follow-up from the HAZOP study

7. Different HAZOP studies from a legal perspective

8. Project v Assessment of a MHF HAZOP

 

Topic 4

Control and Failure Mode Analysis

1. Hazard analysis methods, HAZID, Bow Tie analysis and LOPA modelling

2. A brief study of a process hazard situation with fault tree analysis and event tree

3. Layer of protection analysis model development using Excel formatted software

Topic 5

 Safety Systems

1. Overview of Safety Instrumented Systems (SIS)

2. Management of functional safety

3. Need for targeted safety requirements (such as a HIPPS)

4. Safety life cycle as per IEC 61508 / 61511

Topic 6

Safety Integrity Level Determination

1. Safety Integrity Level (SIL) determination: application examples in group study

2. Development of the Safety Requirements Specification: application example

3. Applicability of SIL to all technologies (E/E/PE and mechanical / hydraulic / pneumatic)

Topic 7

 Safety Instrumented Systems

1. SIS configuration and equipment selection.

2. Principles of safety certified PLCs

3. Principles of high integrity application software

 

Topic 8 and 9

SIS Performance Evaluation

1. The concept of “Fail Safe”

2. SIS Performance evaluation and reliability modelling

3. Practical calculation and development of Excel spread sheet tool

4. Validation, testing and maintenance of SIS installations

 

 

Topic 10 and 11

SIS Project

1. SIS Project launch meeting

2. SIS project consultations

3. SIS project preparations

4. Assignment reviews

5. SIS project presentations and assessments

 

 

Topic 12

Project and Unit Review In the final week students will have an opportunity to review the contents covered so far. Opportunity will be provided for a review of student work and to clarify any outstanding issues. Instructors/facilitators may choose to cover a specialized topic if applicable to that cohort.

Project – due at end of term

Software/Hardware Used

Software

  • Software: N/A

  • Version: N/A

  • Instructions:  N/A

  • Additional resources or files: N/A

Hardware

  • N/A