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IEC 61511 Functional Safety in the Process Industry

IEC 61511 Functional Safety in the Process Industry The New Edition 2 and what does it mean for the Industry.

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IEC 61511 Functional Safety in the Process Industry

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  1. IEC 61511 Functional Safety in the Process Industry The New Edition 2 and what does it mean for the Industry IEC 61508, the foundation for IEC 61511, was first introduced in 2000 and was subsequently updated in 2010. Nevertheless 13 years on from the release of IEC 61511 Edition 1 in 2003 we find ourselves still using the same edition, that is until now. The second edition of IEC 61511 is in the final stages of publication and like with the second edition of IEC 61508 there are some significant changes afoot. So what are the changes and how will these affect the way in which the industry implement the requirements. These plus many other thought provoking changes and questions shall be discussed in this paper.

  2. Lifecycle IEC 61511 follows a Cradle to Grave Approach Disciplines IEC 61511 reaches across several technical disciplines. Key: Process Engineering C&I Engineering Software Engineering Project Management Commissioning Engineering Management Technicians and Ops Management

  3. Process / C&I Engineering Cyber Security Identification of Threats to SIS. • IEC 62443-2-1:2010 • ISO / IEC 27001:2013 • ISA TR 84.00.09 • Safety Integrity Level 4 • More descriptive guidance on preventing the introduction of High SIL levels during Hazard and Risk Analysis (HRA). • Full Quantitative, Fault Tree Analysis (FTA), requirement for High SIL Requirements. • BPCS as an IPL • The use of multiple BPCS as Independent Protection Layers (IPL) in Risk Determination not allowed. • Independence and Separation of BPCS from other IPLs and Initiating Event. • SRS • All requirements now in Clause 10. • Safety Manual • Mandatory for SIS to have a Safety Manual. • Hardware Fault Tolerance • HFT now aligned with IEC 61508:2010 Route 2H which is more appropriate for Proven in Use. • Reliability Data • Now has to be credible, traceable, documented & justified.

  4. Software Engineering Application Program Now defines IEC 61511 as only addressing Limited Variable Language (LVL) all other techniques shall consider IEC 61508:2010 Part 3. Commissioning SIS FAT Planning, Recording and verifying of Factory Acceptance Testing now mandatory. FAT definition now includes field devices and final elements as apposed to just Controller and LVL code. Discrepancies During SAT Analysis of Discrepancies identified during Site Acceptance Testing needs to be recorded and justified. Project Management Revalidation Change to earlier lifecycle phase shall be reviewed to decide if revalidation is required. Impact Analysis Any Modification now requires an Impact analysis to be completed. The Impact analysis shall form part of any FSA conducted on the Modification.

  5. Technician & Operations Manager Periodic Stage 4 FSA Probably the most high profile change is the mandatory requirement for periodic Stage 4 FSA’s. Bypass of SIS Maximum Allowable time shall be defined. Compensating measures for ongoing safe operation shall be provided. Proof Tests Quality and Consistency shall be monitored. A Proof Test after a repair to the SIS is also now mandatory. Data Collection Another significant inclusion is on the collecting of and applying of reliability data associated with the ongoing use of the SIS. Spares Holding With stricter guidance on bypasses it is little wonder a Spares Holding process is also mandatory. HRA Periodic Review of Hazards and Risks is also now mandatory. Proof Test Deferral Stricter control over when and by whom a deferral of a PT is allowed.

  6. Functional Safety Management Audit All lifecycle procedures now require a safety audit. Independence The safety audits have to be carried out by someone independent of the project. Competence Greater emphasis is being placed on having a Competency Management System (CMS). FSM Edition 1 defined a QMS (Against ISO 9001) as necessary however Edition 2 now states any supplier making a claim to FS shall have a Functional Safety Management System (FSMS) i.a.w with IEC 61508 Part 1 Clause 6. Conclusion The second edition has some significant changes and those areas mostly impacted are during the operation and maintenance phases. Functional Safety Management is now also mandatory for all who actively promoting compliance for their products or services to the standards. The author is of the opinion, having reviewed the new edition in detail, that the changes are welcomed and adoption of the new edition will support industry to better manage risk during the operational life of assets thereby promoting a safer working place for all.

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