MSR505

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. Assess and evaluate Hazardous area classification and electrical protection methods with reference to IEC 60079.

Bloom’s level 5

2. Evaluate and execute the HAZOP study.

Bloom’s level 5

3. Compare and criticize hazard and failure analysis models and evaluate safety systems in accordance with IEC 61508 and IEC 61511.

Bloom’s level 5

4. Determine Safety Integrity Level (SIL) and choose the most appropriate Safety Instrumented Systems (SIS) configuration and equipment

Bloom’s level 5

5. Evaluate SIS performance and validate and test SIS installations

Bloom’s level 5

6. Propose a plan for SIS project launch and execution

Bloom’s level 6

Student assessment

Prescribed and Recommended readings

Required Textbook

Practical Electrical Equipment and Installations in Hazardous Areas Geoffrey Bottrill, Derek Cheyne, G. Vijayaraghavan, Steve Mackay, Elsevier, 2005 

Safety Instrumented Systems - A Life-Cycle Approach, By Paul Gruhn, PE, CFSE and Simon Lucchini, CFSE, MIEAust CPEng, 2019  

Goble, William M. Cheddie, Harry. (2005). Safety Instrumented Systems Verification - Practical Probabilistic Calculations

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)
• 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
• 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

 Topic 4 

HAZOP study

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 5

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 6

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 7

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 8

Safety Instrumented Systems

1. SIS configuration and equipment selection.

2. Principles of safety certified PLCs

3. Principles of high integrity application software

 Topic 9

SIS Performance Evaluation - 1

1. The concept of “Fail Safe”

2. SIS Performance evaluation and reliability modelling

Topic 10

SIS Performance Evaluation - 2

1. Practical calculation and development of Excel spreadsheet tool

2. Validation, testing and maintenance of SIS installations

Topic 11

SIS Project

1. SIS Project launch meeting

2. SIS project consultations

3. SIS project preparations

4. Assignment reviews

Topic 12

Presentations and Unit Review

In the final week, students will prepare and present the main findings of their case study as part of Assessment 3. They will also have an opportunity to review the contents covered so far. Opportunities 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.

Software/Hardware Used

Software

• Software: Isograph HAZOP

• Version: Free Trial/ Demo

• Instructions:  N/A

• Additional resources or files: N/A

Hardware

• N/A

Unit Changes Based on Student Feedback