1ABB – United KingdomStuart Nunns
Assuring your Safety Instrumented Systems
as part of your
Process Safety Management Requirements
International TÜV Rheinland Symposium in ChinaFunctional Safety in Industrial Applications18 – 19 October 2011, Shanghai - China
2ABB – United KingdomStuart Nunns
� Significant Industry incidents occurring on a regular basis i.e. Texas City, Buncefield, etc
� Regulatory expectations for improving:-� Process safety management� Functional safety management
� Corporate responsibility and duty of care underpinned by shareholders, colleagues and the general public
� Links to increased process safety management (PSM) requirement relating to layers of protection
� There is an Industry requirement to improve the basis of safe operation, covering:-� Equipment Integrity� Operational Integrity� Competency development
The Need for Additional Safety Assurance
3ABB – United KingdomStuart Nunns
The key concepts to managing safety
Process Safety
Functional Safety
Product Safety
CompetencyAssurance
4ABB – United KingdomStuart Nunns
How are safety assured solutions developed?
Ultimately the end user operators are the drivers o f this requirement
� To achieve these requirements, operator’s must:-� Design and build plants to appropriate technical standards and good practices
� Operate and maintain plants using appropriate safety and qualitymanagement systems� Use competent delivery resources throughout both the project, asset and
operational lifecycle of the equipment in use� Use technology that is fit for purpose
Resulting in delivery of a world class Corporate safety,
performance & sustainability model:-
License to operate
License to operate
Improved safety performanceAvoidance of harm
Improved safety performanceAvoidance of harm
Sustainabilityof the Business
Sustainabilityof the Business
Business excellence
Business excellence
Stakeholder and public confidence
Stakeholder and public confidence
5ABB – United KingdomStuart Nunns
Supply chain essentials
What are the issues in delivery of assured layers o f protection?
� Rightsizing / downsizing, mergers and acquisitions
� Fragmentation of core expertise
� Sourcing credible third party providers of products and services
� Complex supply chain delivery models
6ABB – United KingdomStuart Nunns
Example - Complex Supply chain model
End-user Consortium
End-user Lead Org
EPC / Operator
EPC / Operator
Final Element vendorLogic Solver vendor
End-user Lead Org
End-user Consortium
Regulatory Authority
7ABB – United KingdomStuart Nunns
What problems does this create?
� Ownership / roles & responsibilities?
� Specifications
� Projects costs, timeframes and risk
� Terms & conditions
� Approvals & fitness for purpose
� Regulatory compliance and due diligence
8ABB – United KingdomStuart Nunns
Provision of an assured solution – Key Requirements
Competency Assurance� People - knowledge, experience, training
and qualifications
� Recognised third-party certifiedcompetency schemes
Process Safety� Responsibilities and ‘duty of care’
� Safe manufacturing
� Compliance with regulations
� Sustainable operations
Functional Safety� Application of appropriate safety related
technologies
� Third-party accredited and certified
� methodologies, procedures and systems
� Compliance with standards / good practice
� Compliance with the overall safety lifecycle
Product Safety� Third-party accredited and certified
� SIL capable products
� Performance guarantees
9ABB – United KingdomStuart Nunns
Implementation methodology
Overall installation and commissioning
planning
Overall safety
validation planning
Overall operation and maintenance
planning
Concept1
Overall scope definition2
Hazard and risk analysis3
Overall safety requirements4
Overall safety requirements allocation5
E/E/PE system safety requirements specification9
E/E/PE safety-related system
RealisationRealisation(see E/E/PE system
safety lifecycle)
10
Other risk reductionmeasures
Specification and realisation
11
Overall installation and commissioning12
Overall safety validation13
Overall operation, maintenance and repair14
Decommissioning or disposal16
Overall modification and retrofit15
Overall planning
10 Overall installation and commissioning
planning
Overall safety
validation planning
Overall operation and maintenance
planning
Concept1 Concept1
Overall scope definition2 Overall scope definition2
Hazard and risk analysis3 Hazard and risk analysis3
Overall safety requirements4 Overall safety requirements4
Overall safety requirements allocation5 Overall safety requirements allocation5
E/E/PE system safety requirements specification9 E/E/PE system safety requirements specification9
E/E/PE safety-related system
RealisationRealisation(see E/E/PE system
safety lifecycle)
10 E/E/PE safety-related system
RealisationRealisation(see E/E/PE system
safety lifecycle)
10
Other risk reductionmeasures
Specification and realisation
11 Other risk reductionmeasures
Specification and realisation
11
Overall installation and commissioning12 Overall installation and commissioning12
Overall safety validation13 Overall safety validation13
Overall operation, maintenance and repair14 Overall operation, maintenance and repair14
Decommissioning or disposal16 Decommissioning or disposal16
Overall modification and retrofit15 Overall modification and retrofit15
Overall planning
10
IEC 61508
Decommissioning8
7 Modification
Operation & maintenance6
Installation, commissioning
and validation5
Design & engineering
of the SIS 4
Allocation of
safety functions2
Safety requirements
specification of the SIS3
Hazard & risk analysis1
Ver
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Decommissioning8 Decommissioning8
7 Modification7 Modification
Operation & maintenance6 Operation & maintenance6
Installation, commissioning
and validation5
Installation, commissioning
and validation5
Design & engineering
of the SIS 4 Design & engineering
of the SIS 4
Allocation of
safety functions2
Allocation of
safety functions2
Safety requirements
specification of the SIS3
Safety requirements
specification of the SIS3
Hazard & risk analysis1 Hazard & risk analysis1
IEC 61511
Design & Development of other means of risk
reduction
Decommissioning8 Decommissioning8
7 Modification7 Modification
Operation & maintenance6 Operation & maintenance6
Installation, commissioning
and validation5
Installation, commissioning
and validation5
Design & engineering
of the SIS 4 Design & engineering
of the SIS 4
Allocation of
safety functions2
Allocation of
safety functions2
Safety requirements
specification of the SIS3
Safety requirements
specification of the SIS3
Hazard & risk analysis1 Hazard & risk analysis1
Ver
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Decommissioning8 Decommissioning8
7 Modification7 Modification
Operation & maintenance6 Operation & maintenance6
Installation, commissioning
and validation5
Installation, commissioning
and validation5
Design & engineering
of the SIS 4 Design & engineering
of the SIS 4
Allocation of
safety functions2
Allocation of
safety functions2
Safety requirements
specification of the SIS3
Safety requirements
specification of the SIS3
Hazard & risk analysis1 Hazard & risk analysis1
IEC 61511
Design & Development of other means of risk
reduction
Who?
When?
Where? What?
Why?
10ABB – United KingdomStuart Nunns
The Detail - Processes & Deliverables - 1
Process Safety� Hazard Identification
� Risk assessment & Quantification
� Achievement of ‘ALARP’
� Identification of Protective layers
� SIL determination
� Design and engineering of safety instrumented syste ms
� Provision of evidence supporting the basis of safet y
� Requirements to operate, maintain and modify
11ABB – United KingdomStuart Nunns
The Detail - Processes & Deliverables - 2
Functional Safety
Providers of an engineered instrumented safety syst em and ‘Other’technology solutions as part of your basis of safet y:
� Ensuring compliance to good practice standards i.e, IEC 61511� Using certified:-� Safety products
� Logic Solver� Field Instruments� Final elements
� Engineers� Organisations
� Mapping the appropriate phases of the IEC 61508-615 11 safetylifecycle to the scope of supply
12ABB – United KingdomStuart Nunns
The Detail - Processes & Deliverables - 3
Product SafetySuppliers of safety-instrumented products:-
� Implementing certified processes for the design and engineering ofsafety products – preferably Third party SIL capable
� Providing certified (to IEC 61508) product performa nce – Third partySIL capable
� Continual investment in next generation, best pract ices, meetingmarket requirements and existing installed base
� Providing after sales support and sustainability of the installed base
13ABB – United KingdomStuart Nunns
The Detail - Processes & Deliverables - 4
Competency Assurance
In respect of suppliers:-� Demonstrating long term commitment to the global safety market
� Providing significant investment and development of people for global delivery
� Ensuring staff have adequate and appropriate:
� Training
� Experience
� Knowledge
� Qualifications
� Actively involved in industry focus groups and standards
� Having processes and procedures to manage and deliver succession planning
� Ensuring continued professional development of all staff
14ABB – United KingdomStuart Nunns
So what has to be done?
� Integrating the 4 key concepts
� Discharging responsibilities to competent organisat ions
� Mapping the compliance requirements to the IEC 6150 8 Lifecycle
� Seamlessly integrating PSM with FSM
� More importantly:Providing an overall assured safety solution for SI S
15ABB – United KingdomStuart Nunns
Safety Lifecycle Model – Pre-Design Risk Assessment
� Process Safety Management Systems
� Behavioural Safety & Culture
� Process Hazard Review
� Lifecycle Hazard Studies (including HAZOP 1-6)
� Pressure Relief
� Mechanical Integrity
� SIL Determination
� Hazardous Area Risk Assessmentand Classification
Overall installation and commissioning
planning
Overall safety
validation planning
Overall operation and maintenance
planning
Concept1
Overall scope definition2
Hazard and risk analysis3
Overall safety requirements4
Overall safety requirements allocation5
E/E/PE system safety requirements specification9
E/E/PE safety-related system
RealisationRealisation(see E/E/PE system
safety lifecycle)
10
Other risk reductionmeasures
Specification and realisation
11
Overall installation and commissioning12
Overall safety validation13
Overall operation, maintenance and repair14
Decommissioning or disposal16
Overall modification and retrofit15
Overall planning
10 Overall installation and commissioning
planning
Overall safety
validation planning
Overall operation and maintenance
planning
Concept1 Concept1
Overall scope definition2 Overall scope definition2
Hazard and risk analysis3 Hazard and risk analysis3
Overall safety requirements4 Overall safety requirements4
Overall safety requirements allocation5 Overall safety requirements allocation5
E/E/PE system safety requirements specification9 E/E/PE system safety requirements specification9
E/E/PE safety-related system
RealisationRealisation(see E/E/PE system
safety lifecycle)
10 E/E/PE safety-related system
RealisationRealisation(see E/E/PE system
safety lifecycle)
10
Other risk reductionmeasures
Specification and realisation
11 Other risk reductionmeasures
Specification and realisation
11
Overall installation and commissioning12 Overall installation and commissioning12
Overall safety validation13 Overall safety validation13
Overall operation, maintenance and repair14 Overall operation, maintenance and repair14
Decommissioning or disposal16 Decommissioning or disposal16
Overall modification and retrofit15 Overall modification and retrofit15
Overall planning
10
IEC 61508
16ABB – United KingdomStuart Nunns
Safety Lifecycle Model – Design & Engineering
� SIS Delivery
� Application specific solution
� SIL Achievement
� Specification
� Detailed design
� Realisation (Total Solution)
� TUV Certified Engs
� TUV Certified Safety Centres
� Commissioning
� Validation
Overall installation and commissioning
planning
Overall safety
validation planning
Overall operation and maintenance
planning
Concept1
Overall scope definition2
Hazard and risk analysis3
Overall safety requirements4
Overall safety requirements allocation5
E/E/PE system safety requirements specification9
E/E/PE safety-related system
RealisationRealisation(see E/E/PE system
safety lifecycle)
10
Other risk reductionmeasures
Specification and realisation
11
Overall installation and commissioning12
Overall safety validation13
Overall operation, maintenance and repair14
Decommissioning or disposal16
Overall modification and retrofit15
Overall planning
10 Overall installation and commissioning
planning
Overall safety
validation planning
Overall operation and maintenance
planning
Concept1 Concept1
Overall scope definition2 Overall scope definition2
Hazard and risk analysis3 Hazard and risk analysis3
Overall safety requirements4 Overall safety requirements4
Overall safety requirements allocation5 Overall safety requirements allocation5
E/E/PE system safety requirements specification9 E/E/PE system safety requirements specification9
E/E/PE safety-related system
RealisationRealisation(see E/E/PE system
safety lifecycle)
10 E/E/PE safety-related system
RealisationRealisation(see E/E/PE system
safety lifecycle)
10
Other risk reductionmeasures
Specification and realisation
11 Other risk reductionmeasures
Specification and realisation
11
Overall installation and commissioning12 Overall installation and commissioning12
Overall safety validation13 Overall safety validation13
Overall operation, maintenance and repair14 Overall operation, maintenance and repair14
Decommissioning or disposal16 Decommissioning or disposal16
Overall modification and retrofit15 Overall modification and retrofit15
Overall planning
10
IEC 61508
17ABB – United KingdomStuart Nunns
Safety Lifecycle Model – Operations and Maintenance
� Organisational Culture / Change
� Human Reliability Assessment
� Safety Critical Procedure Assessment
� Staffing Levels and Workload Assessment
� Pre Start-up Safety Review
� Legacy Systems Review
� Control Room Performance Assessment
� Alarm Management Health Check
� Safe Systems of Work
� Management of Change
� Mechanical Integrity
� Incident Investigation Support
Overall installation and commissioning
planning
Overall safety
validation planning
Overall operation and maintenance
planning
Concept1
Overall scope definition2
Hazard and risk analysis3
Overall safety requirements4
Overall safety requirements allocation5
E/E/PE system safety requirements specification9
E/E/PE safety-related system
RealisationRealisation(see E/E/PE system
safety lifecycle)
10
Other risk reductionmeasures
Specification and realisation
11
Overall installation and commissioning12
Overall safety validation13
Overall operation, maintenance and repair14
Decommissioning or disposal16
Overall modification and retrofit15
Overall planning
10 Overall installation and commissioning
planning
Overall safety
validation planning
Overall operation and maintenance
planning
Concept1 Concept1
Overall scope definition2 Overall scope definition2
Hazard and risk analysis3 Hazard and risk analysis3
Overall safety requirements4 Overall safety requirements4
Overall safety requirements allocation5 Overall safety requirements allocation5
E/E/PE system safety requirements specification9 E/E/PE system safety requirements specification9
E/E/PE safety-related system
RealisationRealisation(see E/E/PE system
safety lifecycle)
10 E/E/PE safety-related system
RealisationRealisation(see E/E/PE system
safety lifecycle)
10
Other risk reductionmeasures
Specification and realisation
11 Other risk reductionmeasures
Specification and realisation
11
Overall installation and commissioning12 Overall installation and commissioning12
Overall safety validation13 Overall safety validation13
Overall operation, maintenance and repair14 Overall operation, maintenance and repair14
Decommissioning or disposal16 Decommissioning or disposal16
Overall modification and retrofit15 Overall modification and retrofit15
Overall planning
10
IEC 61508
18ABB – United KingdomStuart Nunns
Safety Lifecycle Model – Operations and Maintenance
� Reliability and Operations Improvement
� Modifications , upgrades
� Brownfield project delivery
� 24/7 Service Level Agreements
� TUV Certified service organisation
� Performance assurance
� Testing and repairs
� Operating and Maintenance Procedures
Overall installation and commissioning
planning
Overall safety
validation planning
Overall operation and maintenance
planning
Concept1
Overall scope definition2
Hazard and risk analysis3
Overall safety requirements4
Overall safety requirements allocation5
E/E/PE system safety requirements specification9
E/E/PE safety-related system
RealisationRealisation(see E/E/PE system
safety lifecycle)
10
Other risk reductionmeasures
Specification and realisation
11
Overall installation and commissioning12
Overall safety validation13
Overall operation, maintenance and repair14
Decommissioning or disposal16
Overall modification and retrofit15
Overall planning
10 Overall installation and commissioning
planning
Overall safety
validation planning
Overall operation and maintenance
planning
Concept1 Concept1
Overall scope definition2 Overall scope definition2
Hazard and risk analysis3 Hazard and risk analysis3
Overall safety requirements4 Overall safety requirements4
Overall safety requirements allocation5 Overall safety requirements allocation5
E/E/PE system safety requirements specification9 E/E/PE system safety requirements specification9
E/E/PE safety-related system
RealisationRealisation(see E/E/PE system
safety lifecycle)
10 E/E/PE safety-related system
RealisationRealisation(see E/E/PE system
safety lifecycle)
10
Other risk reductionmeasures
Specification and realisation
11 Other risk reductionmeasures
Specification and realisation
11
Overall installation and commissioning12 Overall installation and commissioning12
Overall safety validation13 Overall safety validation13
Overall operation, maintenance and repair14 Overall operation, maintenance and repair14
Decommissioning or disposal16 Decommissioning or disposal16
Overall modification and retrofit15 Overall modification and retrofit15
Overall planning
10
IEC 61508
19ABB – United KingdomStuart Nunns
Introduction to the ABB Assured Solution
Process Safety
Functional Safety
Product Safety
Competency Assurance
� Global Footprint
� Certified Organisations
� Certified Products
� Certified Engineers
� Complete lifecycle compliance
Overall installation and commissioning
planning
Overall safety
validation planning
Overall operation and maintenance
planning
Concept1
Overall scope definition2
Hazard and risk analysis3
Overall safety requirements4
Overall safety requirements allocation5
E/E/PE system safety requirements specification9
E/E/PE safety-related system
RealisationRealisation(see E/E/PE system
safety lifecycle)
10
Other risk reductionmeasures
Specification and realisation
11
Overall installation and commissioning12
Overall safety validation13
Overall operation, maintenance and repair14
Decommissioning or disposal16
Overall modification and retrofit15
Overall planning
10 Overall installation and commissioning
planning
Overall safety
validation planning
Overall operation and maintenance
planning
Concept1 Concept1
Overall scope definition2 Overall scope definition2
Hazard and risk analysis3 Hazard and risk analysis3
Overall safety requirements4 Overall safety requirements4
Overall safety requirements allocation5 Overall safety requirements allocation5
E/E/PE system safety requirements specification9 E/E/PE system safety requirements specification9
E/E/PE safety-related system
RealisationRealisation(see E/E/PE system
safety lifecycle)
10 E/E/PE safety-related system
RealisationRealisation(see E/E/PE system
safety lifecycle)
10
Other risk reductionmeasures
Specification and realisation
11 Other risk reductionmeasures
Specification and realisation
11
Overall installation and commissioning12 Overall installation and commissioning12
Overall safety validation13 Overall safety validation13
Overall operation, maintenance and repair14 Overall operation, maintenance and repair14
Decommissioning or disposal16 Decommissioning or disposal16
Overall modification and retrofit15 Overall modification and retrofit15
Overall planning
10
IEC 61508
Decommissioning8
7 Modification
Operation & maintenance6
Installation, commissioning
and validation5
Design & engineering
of the SIS 4
Allocation of
safety functions2
Safety requirements
specification of the SIS3
Hazard & risk analysis1
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Decommissioning8 Decommissioning8
7 Modification7 Modification
Operation & maintenance6 Operation & maintenance6
Installation, commissioning
and validation5
Installation, commissioning
and validation5
Design & engineering
of the SIS 4 Design & engineering
of the SIS 4
Allocation of
safety functions2
Allocation of
safety functions2
Safety requirements
specification of the SIS3
Safety requirements
specification of the SIS3
Hazard & risk analysis1 Hazard & risk analysis1
IEC 61511
Design & Development of other means of risk
reduction
Decommissioning8 Decommissioning8
7 Modification7 Modification
Operation & maintenance6 Operation & maintenance6
Installation, commissioning
and validation5
Installation, commissioning
and validation5
Design & engineering
of the SIS 4 Design & engineering
of the SIS 4
Allocation of
safety functions2
Allocation of
safety functions2
Safety requirements
specification of the SIS3
Safety requirements
specification of the SIS3
Hazard & risk analysis1 Hazard & risk analysis1
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Decommissioning8 Decommissioning8
7 Modification7 Modification
Operation & maintenance6 Operation & maintenance6
Installation, commissioning
and validation5
Installation, commissioning
and validation5
Design & engineering
of the SIS 4 Design & engineering
of the SIS 4
Allocation of
safety functions2
Allocation of
safety functions2
Safety requirements
specification of the SIS3
Safety requirements
specification of the SIS3
Hazard & risk analysis1 Hazard & risk analysis1
IEC 61511
Design & Development of other means of risk
reduction
Seamless Integration of the key concepts to a best practice delivery model
20ABB – United KingdomStuart Nunns
How does ABB deliver safety assured solutions?
� Global footprint via Safety Execution Centres (SEC’s)
� Design, engineer and integrate using a third party certified functional safety management system
� Provide both process safety and functional safety consultancy
� Provide full service support
� Deploy certified competent staff
� Provide complete services and deliverables for all the phases of the IEC 61508/61511 lifecycle
21ABB – United KingdomStuart Nunns
SEC delivery locations
ABB´s assured solution global delivery footprint
22ABB – United KingdomStuart Nunns
Conclusions
The ABB Methodology:-� Deliver the whole safety lifecycle on a global approach� Robust basis of safety developed� Assured protective systems solutions� Traceable, auditable compliant systems and products� Competency assurance
The ABB Assurance:-� Meeting your regulatory and legal requirements� Supporting your ability to demonstrate duty of care� Facilitating your Stakeholder confidence� Delivering ‘Fit for purpose’ Technology, Solutions and Service Support
Assured and certified products, services, delivery and execution