This course is for engineers and technicians who wish to develop their knowledge of the design and implementation of safety instrumented systems as applied to industrial processes. Safety control systems are widely used in hazardous processes to protect people, the environment and equipment against serious harm. Many countries look for compliance to international standards IEC 61508 and IEC 61511 as a benchmark of acceptable quality in design and management of safety controls.

This course will explain the key requirements of the IEC 61511 standard for all stages of the safety project from hazard and risk assessment studies through to hardware and software engineering and on to the maintenance and proof testing regimes. Practical examples and discussions will assist you to develop your skills in this most important aspect of instrument engineering.

COURSE OBJECTIVES:

After completing this course, you will understand:

  • Fundamentals of risk assessment and the role of safety regulations
  • Process hazard study methods including HAZOP
  • Principles of risk reduction by Safety Instrumented Systems (SIS)
  • The differences between a basic control system and an SIS
  • The roles of standards IEC 61508 and IEC 61511
  • The principles and application of the safety life cycle for project management
  • The meaning and implications of Safety Integrity Levels (SILs)
  • How to use fault tree analysis to predict accident rates and failure rates
  • How SIL targets are determined
  • The role of alarms in safety critical applications
  • How to design the SIS to meet IEC requirements for SIL targets
  • Key features of safety certified PLCs
  • Understand failure modes and the concepts of fault tolerance
  • How to calculate failure probabilities for single and redundant SIS designs
  • How to select instruments and controllers suitable for safety systems
  • How to manage the application software project for your safety system
  • Methods for avoidance of spurious trips
  • How to optimise proof testing intervals  

Course Outline

MODULE 1: Overview of Safety Instrumented Systems

  • Safety system basics with an example SIS
  • Hazards, risks and risk reduction
  • Principles of safety management
  • Functional safety standards IEC 61508/61511
  • Setting SIL targets
  • Designing to meet SIL targets
  • Cost of ownership

MODULE 2: Safety Life Cycle Models

  • Purpose of life cycle models
  • IEC 61511 requirements
  • Step by step activities

MODULE 3: Hazard Study Methods

  • Hazard studies and project stages
  • Hazard identification methods
  • HAZOP method
  • Developing SIS requirements
  • Fault tree analysis

MODULE 4: Risk Reduction by SIS

  • Deciding risk targets
  • Principle of ALARP and tolerable risk
  • Layers of protection and role of alarms
  • Risk reduction models
  • Preparing a safety requirements Specification

MODULE 5: SIL Determination Methods

  • Quantitative and risk matrix methods
  • Risk graphs
  • Layers of protection analysis
  • Practical examples

MODULE 6: Designing SIS Structures

  • Design procedure steps
  • IEC 61511 guidelines
  • Architectures and fault tolerance
  • Choosing the right structures for the job

MODULE 7: Selecting Instruments for Safety Duties

  • Switches versus transmitters
  • Failure modes of sensors and actuators
  • Minimising dangerous failures
  • Qualification by design and certification
  • Qualification by prior use
  • Smart instruments and diagnostic
  • Coverage

MODULE 8: Reliability Analysis

  • Purposes of reliability calculations
  • SIS failure modes, safe and dangerous
  • Formulae and how to use them
  • Worked examples
  • Obtaining reliability data and the
  • problems
  • Review of software tools

MODULE 9: Safety-certified PLCs

  • Logic solvers, old and new
  • Development of safety PLCs
  • Hardware and software features
  • Review of industry types
  • Communications and networking
  • Integrated basic and safety control

MODULE 10: Application Software for Safety Duties

  • The problem with software
  • IEC software life cycle models
  • Application software steps
  • Factory acceptance testing
  • Quality assurance and certification

MODULE 11: Documentation and Management

  • Documents needed for the SIS project
  • Verification and validation
  • Operations
  • Management of change

MODULE 12: Diagnostics and Proof Testing

  • Proof testing and why it is needed
  • Testing of sensors
  • Partial closure testing of valves
  • Optimising the proof test interval

NB: The course description of all EIT "Certificate" courses has been changed to "Professional Certificate of Competency". Some course brochures are not yet updated. The actual certificate received by successful students will include the new title.


 

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How can an e-learning course be interactive?

Boredom can be a real danger, however, we use an interactive approach to our e-Learning – with live sessions instead of recordings.  The webinar software allows everyone to interact and involves participants in group work; including hands-on exercises with simulation software and remote laboratories where possible.  You can communicate with text messages, or live VoIP speech, or can even draw on the whiteboard during the sessions.

 

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