Process Safety Management and Functional Safety Management. Spot the difference

Transcription

1 Process Safety Management and Functional Safety Management. Spot the difference A few key points for those Directors and Managers responsible for overseeing safety trips by The Association SAFETY INSTRUMENTED SYSTEMS are too important to leave to chance! DISCLAIMER: Whilst every effort has been made to ensure the accuracy of the information contained in this document neither The Association nor its members will assume any liability for any use made thereof.

2 Important and surprising fact Every process plant, including yours, has safety trips Some of those safety trips are high reliability or high integrity, therefore IEC61508 or one of the related group of standards, such as IEC61511, applies.

3 BS EN 61508: Hazard & Risk Analysis The Safety Instrumented System Fills the gap IF the other protections are present TOLERABLE RISK LEVEL UNACCEPTABLE RISK LEVEL IDENTIFIED RISK Required Risk Reduction By SIL System By Other Technology (Relief system / Vessel design etc.) By External Factors (Location /Bunding etc)

4 Important and surprising fact Since SIL rated trips fill the gap and make the risk TOLERABLE to the company,... the SIL and its PFDavg are only true IF all of the other layers of protection are present and working. This means that Functional Safety Management is about maintaining ALL of the layers of safety protection so that each SIL and its PFDavg remain true. FSM is about maintaining all of the safety. FSM is NOT strangely restricted to the SIL rated system.

5 The Association does not believe in doing the same work twice just because it appears in more than one standard. Process safety management is good practice for any company but it is not mandatory by contrast Functional safety management is mandatory under IEC61508 Part 1

6 Approved Code of Practice In countries around the world IEC61508 and IEC61511 are mandated. Take, for example, the UK: D.S.E.A.R. is the... Dangerous Substances and Explosive Atmospheres Regulations DSEAR in the UK is mainly ATEX, but it is not just ATEX, and DSEAR applies to everyone ATEX in EUROPE is EAR, the Explosive Atmospheres Regulations... but we have the Dangerous Substances and... So DSEAR is more than just ATEX. BS EN appears in the H.S.E.'s Approved Code of Practice for DSEAR, L138, 1 as well as BS EN See Paragraph 87 of 2 nd edition of the Approved Code of Practice, L138

7 Functional safety management ( FSM ) Sub-standards, such as IEC61511 for the process industries, reference the master standard IEC So one cannot do IEC61511 without IEC61508 as well. FSM appears in the master standard in the normative Part 1 at clause 6 FSM also appears in each of the sub-standards (For example FSM appears in IEC61511 for the process industries at Part 1 clause 5) Many of the Process Safety Management guides are not mandatory so we will use the Energy Institute guidance as an example. so let s compare them in the following slides:

8 FSM vs PSM CASS 32 is the FREE system for Functional Safety Management. The Energy Institute produced a High level framework for process safety management These are the two schemes used to enable the comparison.

9 FSM vs PSM The requirements of the safety management: Policy: Organisation and responsibilities: The relevant lifecycle phases to my work: Techniques and measures conformance plan: Non-conformance plan: CASS 32 ref: Part 3 item 1 Functional safety management Part 3 item 2 policy Part 3 item 3 organisation, structure & responsibilities Part 3 items 4 and 5 Relevant lifecycle phases and relationship with structure & policy Part 3 item 6 Techniques & measures Part 3 item 7 Nonconformance plan E.I. Guide ref: Section 1.2, Scope and application Element 1 item 1.1 to 1.4 inclusive Element 1 item 1.5 to 1.15 inclusive Element 2 all items Element 6, 7 and 8, all items Element 10, 11 and 12. See particularly 11.7

10 FSM vs PSM Competence assessment: Procedure for handling hazardous incidents and near misses: The lifetime of the safety trip - Operating and Maintenance Audit CASS 32 ref: Part 3 item 8 competence assessment process Part 3 item 9 hazardous incident procedure and handling near misses Part 3 item 10 Procedure for operating and maintenance analysis Part 3 item 11 Functional Safety audit process E.I. Guide ref: Element 3, particularly element 3.2 to 3.5 inclusive. Element 6, particularly element 6.10 to 6.15 inclusive, and Element 19 all cases. Elements 16 and 17, all cases Element 20 all cases

11 FSM vs PSM Change management: Maintaining information from sources outside work: CASS 32 ref: Part 3 item 12 modification process for safety systems Part 3 item 13 maintaining information on hazards from industry E.I. Guide ref: Element 8.4 and Element 12 all cases Not fully covered Configuration management: Training: Emergency services plans: Review of safety management Part 3 item 14 configuration management procedures Part 3 item 15 training Part 3 item 15 emergency services Part 3 item 16 formal reviews Element 13 all cases Elements 3.9, 3.11, 4.4 and 4.5 Element 14 Element 1.15, and at the end of each element

12 Conclusion Functional Safety Management and Process Safety Management are largely the same. Functional Safety Management is mandatory. FSM appears in the master standard in the normative Part 1 at clause 6 FSM also appears in each of the sub-standards (For example FSM appears in IEC61511 for the process industries at Part 1 clause 5) Many of the Process Safety Management guides are not mandatory so we have used the Energy Institute guidance as an example. so comply with FSM and add what is necessary for other safety management schemes.