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

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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

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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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