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How to Implement an ANSI ISA 84 Compliant Safety System

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  • SIS ISA84 ComplianceCopyright Yokogawa Electric CorporationJanuary 27th, 2015

    - 1 -

    How To Implement an ANSI/ISA 84 Compliant Safety System

    Jan N. de BreetTechnical Solutions Consultant

    Yokogawa Corporation of America

  • SIS ISA84 ComplianceCopyright Yokogawa Electric CorporationJanuary 27th, 2015

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    Presenter

    Jan de Breet

    Technical Solutions ConsultantSafety Instrumented SystemsYokogawa Corporation of America

    o Jan de Breet is a Senior Technical Solutions Consultant at Yokogawa Corporation of America for safety instrumented systems solutions, based in the Sugar Land, Texas office.

    o Since 1988, Jan de Breet has been working in the safety instrumented systems industry in research and development, field service, operations, sales and marketing.

  • SIS ISA84 ComplianceCopyright Yokogawa Electric CorporationJanuary 27th, 2015

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    Introduction

    Why replace a safety system?Why ANSI/ISA 84 compliance?ANSI/ISA 84 OverviewWhat does it require to comply?Why Yokogawa - ProSafe-RS?

  • - 4 -SIS ISA84 ComplianceCopyright Yokogawa Electric CorporationJanuary 27th, 2015

    Why replace a safety system?Current Situation

  • SIS ISA84 ComplianceCopyright Yokogawa Electric CorporationJanuary 27th, 2015

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    Current Situation

    Aging installed base of safety systemsOld relay and pneumatic need to be replaced.Old technologies, compatibility issuesDisappearing knowledge/experienceEnd of product life, no more supportHigh reliability leads to longer (= too long) use.Variety of different systems through acquisitionSpecialized knowledge for each brand required

    Source: ARC Advisory Group - Process Safety Systems

  • - 6 -SIS ISA84 ComplianceCopyright Yokogawa Electric CorporationJanuary 27th, 2015

    Why ANSI/ISA 84 Compliance?Good Engineering Practice

  • SIS ISA84 ComplianceCopyright Yokogawa Electric CorporationJanuary 27th, 2015

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    Why ANSI/ISA 84 Compliance?

    Major incidentsLiability, InsuranceEven with good personal safety management plants are still at risk from process hazards

    OSHA 29 CFR PSM 1910 Good Engineering Practice Grandfather Clause

  • SIS ISA84 ComplianceCopyright Yokogawa Electric CorporationJanuary 27th, 2015

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    Why ANSI/ISA 84 Compliance?

    Grandfather Clause"For existing SIS designed and constructed in accordance with codes, standards, or practices prior to the issue of this standard, the owner/operator shall determine that the equipment is designed, maintained, inspected, tested and operating in a safe manner.

    Issue: 2004 (and 1996) Only very basic upgrades possible, e.g. repairs Very hard to keep up-to-date

    De Facto not possible anymore

  • SIS ISA84 ComplianceCopyright Yokogawa Electric CorporationJanuary 27th, 2015

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    Why ANSI/ISA 84 Compliance?

    ISA 84: The Most Widely Used Standard

  • - 10 -SIS ISA84 ComplianceCopyright Yokogawa Electric CorporationJanuary 27th, 2015

    ANSI/ISA 84An Overview

  • SIS ISA84 ComplianceCopyright Yokogawa Electric CorporationJanuary 27th, 2015

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    ANSI/ISA 84 Overview

    ANSI/ISA-84.00.01-2004 Functional Safety Safety Instrumented Systems for the Process Industry Sector

    Part 1 Describes the safety life cycle and all the requirements that apply.

    Part 2 Guidelines for the application of part 1.

    Part 3 Examples of methods to determine the required safety integrity level.

  • SIS ISA84 ComplianceCopyright Yokogawa Electric CorporationJanuary 27th, 2015

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    ANSI/ISA 84 Overview

    Main Characteristics Management of Functional Safety Safety Life Cycle Pipe-to-Pipe Approach Quantitative Safety Assessment

  • SIS ISA84 ComplianceCopyright Yokogawa Electric CorporationJanuary 27th, 2015

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    ANSI/ISA 84 Overview

    Management of Functional Safety Must have a Functional Safety Management (FSM)

    system in place Specifies all management and technical activities

    necessary to achieve required functional safety Life cycle Procedures Competencies, Responsibilities Verification and Validation Procedures Auditable Traceable

  • SIS ISA84 ComplianceCopyright Yokogawa Electric CorporationJanuary 27th, 2015

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    ANSI/ISA 84 Overview

    Safety Life Cycle

  • SIS ISA84 ComplianceCopyright Yokogawa Electric CorporationJanuary 27th, 2015

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    ANSI/ISA 84 Overview

    Pipe-to-Pipe Approach Safety Instrumented Function, SIF

  • SIS ISA84 ComplianceCopyright Yokogawa Electric CorporationJanuary 27th, 2015

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    ANSI/ISA 84 Overview

    Quantitative Safety Assessment

    => Risk Reduction

    Expressed as Safety Integrity Level, SIL

    SIF

  • SIS ISA84 ComplianceCopyright Yokogawa Electric CorporationJanuary 27th, 2015

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    ANSI/ISA 84 Life Cycle Overview

    HAZARD and Risk Assessment As Low As Reasonably Practicable (ALARP) and

    tolerable risk concepts Semi-quantitative method The safety layer matrix method Determination of the required safety integrity levels

    a semi qualitative method: calibrated risk graph Determination of the required safety integrity levels

    a qualitative method: risk graph Layer of protection analysis (LOPA)

  • SIS ISA84 ComplianceCopyright Yokogawa Electric CorporationJanuary 27th, 2015

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    ANSI/ISA 84 Life Cycle Overview

    HAZARD and Risk Assessment Team consists of:

    Process designers Instrumentation engineers Safety engineers Electrical engineers Mechanical engineers Operators Maintenance engineers

    Facilitator

  • SIS ISA84 ComplianceCopyright Yokogawa Electric CorporationJanuary 27th, 2015

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    ANSI/ISA 84 Life Cycle Overview

    HAZARD and Risk Assessment

  • SIS ISA84 ComplianceCopyright Yokogawa Electric CorporationJanuary 27th, 2015

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    ANSI/ISA 84 Life Cycle Overview

    Allocation of Safety Functions

    HAZOP Available Layers of Protection

    SIS

  • SIS ISA84 ComplianceCopyright Yokogawa Electric CorporationJanuary 27th, 2015

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    ANSI/ISA 84 Life Cycle Overview

    Allocation ofSafety Functions

  • SIS ISA84 ComplianceCopyright Yokogawa Electric CorporationJanuary 27th, 2015

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    ANSI/ISA 84 Life Cycle Overview

    Safety Requirements Specifications Description of the safety functions and SIL I/O Assignment to SIFs Safe state of the process (open/closed, de-/energized) Process inputs and trip points, Process outputs and actions Functional relationships, failure modes Manual shutdown and reset requirements Maintenance/bypassing requirements Safe state Process safety time and Response time

    requirements Operator interfaces modes: start-up, steady operation,

    shut down. Foreseeable abnormal conditions Requirements for starting-up and shutting-down

  • SIS ISA84 ComplianceCopyright Yokogawa Electric CorporationJanuary 27th, 2015

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    ANSI/ISA 84 Life Cycle Overview

    Safety Requirements Specifications

    References to several documents, e.g.: C&E diagrams or Logic diagrams, describing the

    functionality of the SIS I/O lists defining all inputs and outputs to/from the SIS Narratives Safety philosophy Shutdown hierarchy Maintenance override philosophy

  • SIS ISA84 ComplianceCopyright Yokogawa Electric CorporationJanuary 27th, 2015

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    ANSI/ISA 84 Life Cycle Overview

    The SIS design Availability System Architecture Sensors Final Elements Logic Solver Failure Modes and PFD Calculations Design Principles Failure Modes Necessary calculation parameters Proof Testing Common Cause Reliability Data and calculation methodology

  • SIS ISA84 ComplianceCopyright Yokogawa Electric CorporationJanuary 27th, 2015

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    ANSI/ISA 84 Life Cycle Overview

    The SIS Design

  • SIS ISA84 ComplianceCopyright Yokogawa Electric CorporationJanuary 27th, 2015

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    ANSI/ISA 84 Life Cycle Overview

    Application Software

    ANSI/ISA 84 gives this very much attention Many clauses to comply with Has its own life cycles

    Use a certified (IEC61508) system and programming tools

    Combine hardware and software life cycle Describe this well in project documentation

  • SIS ISA84 ComplianceCopyright Yokogawa Electric CorporationJanuary 27th, 2015

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    ANSI/ISA 84 Life Cycle Overview

    Installation, Commissioning and Validation

    Installation and Commissioning Plan this well Document all activities Document changes (e.g. resolving issues)

    Validation (SAT) Safety Validation Plan Validate that the requirements in the SRS are met Plan this well, from the start

  • SIS ISA84 ComplianceCopyright Yokogawa Electric CorporationJanuary 27th, 2015

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    ANSI/ISA 84 Life Cycle Overview

    Functional Assessment Has a hazard and risk analysis been carried out Are the recommendations from this analysis implemented or

    resolved Are design change procedures in place and properly used Are recommendations from earlier assessments resolved Is the SIS designed and installed in accordance with the SRS Are the procedures for operation, maintenance and modification

    of the SIS ready Has the validation of the SIS been done, and are all

    recommendations resolved Are the operators and maintenance engineers educated and

    trained Is there a plan for further safety assessments in place

  • SIS ISA84 ComplianceCopyright Yokogawa Electric CorporationJanuary 27th, 2015

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    ANSI/ISA 84 Life Cycle Overvie

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