Training Session - Lunch and Learn
Understanding Safety Integrity Level (SIL)
Dinesh Vijay Bhurke
13th March 2014
Content
Why Safety ?
Basic Concepts, Definitions, Acronyms
SIL concept
Standards – IEC, ISA
Layer of Protection concept
Risk Management
SIL Assignment /Assessment (Risk Reduction)
Hazard Matrix method
Risk Graph method
LOPA method
Training: Lunch & Learn Session 2
Why Safety ?
Chernobyl, Nuclear Power Plant,
April 1986
Piper Alpha Platform, July 1986
Bhopal Gas Leak disaster
WORLD’s WORST
INDUSTRIAL DISTASTERS
Training: Lunch & Learn Session 3
Why Safety ?
WORLD’s WORST INDUSTRIAL DISTASTERS
Source: Emerson’s PlantWeb University, SIS 103 - Safety Standards.
Training: Lunch & Learn Session 4
Introduction
What is Safety ?
Freedom from unacceptable risk.
Fatality Rates
Per Year Per Year
Occupation Staying at home
Chemical Industry 5 in 1,00,000 Electrocution 1.2 in 10,00,000
Mining(Coal) 2 in 10,000
Travel
Involuntary Air(Scheduled) 2 in 10,00,000
Lightining 1 in 100,00,000 Train 3 in 10,00,000
Fire 2 in 1,00,000 Car 2 in 10,000
Run over 6 in 1,00,000 Motor Cycle 2 in 100
What is Risk?
Frequency of occurrence of harm X Severity of that harm.
FREQUENCY
Risk without any Protection
Reduction
Tolerable Risk
CONSEQUENCES
Why Safety?
Pres..bozza.. 5
ott. ’14
Safety Vs. Availability
People Outside People Inside
Plant Plant
Environment
Corporate Off-Spec
Assets
Image Production
6
Acronyms
• SIL: Safety Integrity Level
• SIF: Safety Instrumented Function
• SIS: Safety Instrumented System (ESD)
• SFF: Safe Failure Fraction = (ƛs+ ƛdd)/ (ƛs+ ƛdd+ ƛdu)
• SRS: Safety Requirements Specification
• STR: Spurious Trip Rate
• RRF: Risk Reduction Factor
• PFD: Probability of Failure on Demand
• PFDavg, SIF: Probability that the SIF fails to respond to a Process Demand
(PFDavg, SIF = PFDsensor + PFDlogic solver + PFDFE + PFDpower supply)
• MTTF: Mean Time To Failure (e.g. 76 yrs)
• MTTR: Mean Time To Repair (e.g. 1 month)
• MTBF: Mean Time Between Failure (= MTTF + MTTR)
• ALARP: As Low As Reasonably Practicable
• IPL: Independent Protection Layer
• FMEA: Failure Mode and Effect Analysis
• FTA: Fault Tree Analysis
• LOPA: Layer of Protection Analysis
• HAZOP: Hazard and Operability Analysis
Training: Lunch & Learn Session 7
Understanding Safety Integrity Level
(SIL)
• What does SIL mean?
– Safety Integrity Level
– A measure of probability to fail on demand(PFD) of the SIS.
– It is statistical representation of the integrity of the SIS when a
process demand occurs.
– A demand occurs whenever the process reaches the trip
condition and causes the SIS to take action.
– There are 4 SIL levels. SIL Levels are measures of how we
achieve function safety.
– Applies to the complete safety function/loop
– Higher SIL means
Stricter requirements.
Safety Function fails less and thus plant protection is available more.
Training: Lunch & Learn Session 8
Understanding Safety Integrity Level
(SIL)
• SIL is how we measure the performance of safety functions
carried out by safety instrumented systems
• SIL must be viewed from 3 perspectives
– Process Owners
Which Safety function do I need and how much do I need?
– Engg. Companies, System Integrators, Product Developers
How do I Build SIL compliant safety devices, function or systems?
– Plant Operators
How do I operate, maintain and repair safety functions and systems to
maintain identified SIL levels?
Training: Lunch & Learn Session 9
SIL STANDARDS
IEC-61508
Generic Used By Vendors
(1998 & 2010)
Calls Safety system as
E/E/PES
ESD/HIPPS/BMS/FGS
Industry Specific-Used by
IEC-61511 ISA S84 Designers & End users.
(2003) (1996 & 2004)
Calls Safety system as
SIS
Process Industry
ISO 26262 IEC-61513 IEC 62061 IEC 62279
EN 50128
Automotive Nuclear Machinery Railways
Training: Lunch & Learn Session 10
SIL Classification
SIL Probability Category
1 1 in 10 to 1 in 100
2 1 in 100 to 1 in 1,000
3 1 in 1,000 to 1 in 10,000
4 1 in 10,000 to 1 in 100,000
1 in 10 means, the function will fail once in a total of 10 process demands
1 in 1000 means, the function will fail once in a total of 1000 process demands
Training: Lunch & Learn Session 11
SIL Classification
Safety Integrity Levels
SIL Probability of failure on demand
Level (Demand Mode of Operation) Risk Reduction Factor
SIL 4 >=10-5 to <10-4 >=0.00001 to <0.0001 100000 to 10000
SIL 3 >=10-4 to <10-3 >=0.0001 to <0.001 10000 to 1000
SIL 2 >=10-3 to <10-2 >=0.001 to <0.01 1000 to 100
SIL 1 >=10-2 to <10-1 >=0.01 to <0.1 100 to 10
Training: Lunch & Learn Session 12
Concept of Layers of Protection
Training: Lunch & Learn Session 13
Concept of Layers of Protection
Training: Lunch & Learn Session 14
Concept of Layers of Protection
Training: Lunch & Learn Session 15
Multiple Initiators tripping one
Final Element
SIF-1
Initiators
Final
Element
SIF-2
Logic Solver
SIF-3
Training: Lunch & Learn Session 16
One Initiator tripping multiple
Final Elements
Final
Elements
SIF-1
Initiator
SIF-2
Logic Solver
SIF-3
Training: Lunch & Learn Session 17
Overall Safety Instrumented
System showing SIFs
Final Control
Sensors Elements
1 A
SIF 1 2 B
SIF 2 C
3
Logic
Solver
SIF 3 4 D
5
E
SIF 4 F
6
Training: Lunch & Learn Session 18
Risk Management
Three important steps
• Identify Hazards / Hazardous events
• Analyze /Assess the Hazards/Hazardous events
• Reduce risk where necessary
Training: Lunch & Learn Session 19
Assigning the SIL with Hazard Matrix
Training: Lunch & Learn Session 20
Assigning the SIL – Risk Reduction
Training: Lunch & Learn Session 21
Assigning the SIL – Risk Reduction
Training: Lunch & Learn Session 22
Assigning the SIL – Risk Reduction
Training: Lunch & Learn Session 23
Assigning the SIL – Risk Reduction
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Assigning the SIL with Risk Graph
Training: Lunch & Learn Session 25
Risk reduction with LOPA
Training: Lunch & Learn Session 26
Risk reduction with LOPA
Training: Lunch & Learn Session 27
Suggestions / Feedback
Thank You
28
Suggestions / Feedback
There could be a next session ……
1. Introduction to Functional Safety.
2. Hardware Design.
3. SIL Verification methods.
Strictly on popular demand
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