Plant Hazard Analysis and Safety Instrumentation Systems serves as a comprehensive guide to the development of safety instrumented system (SIS), outlining the connections between SIS requirements, process hazard analysis, SIS lifecycle, implementation, safety analysis, and realization in control systems. The book also explores the impact of recent advances, such as SIL, SIS, and Fault Tolerance. In line with technological developments, it covers safety in wireless systems as well as in Industrie 4.0 and Digital Transformation.
Plant Hazard Analysis and Safety Instrumentation Systems incorporates practical examples throughout the book. It covers safety analysis and realization in control systems, providing up-to-date descriptions of modern concepts like SIL, SIS, and SIF. The inclusion of security issues alongside safety issues is particularly relevant for the programmable systems used in modern plant instrumentation systems. The new chapters in this updated edition address security concerns
crucial for programmable systems in modern plants- including topics such as discussion of hazardous atmospheres and their impact on electrical enclosures, the use of IS circuits, and their links to safety considerations in major developmental areas, including IIoT, Cloud computing, wireless safety, Industry 4.0, and digital transformation.
This book is a valuable resource for Process Control Engineers, Process Engineers, Instrumentation Engineers, Safety Engineers, and Mechanical/Manufacturing Engineers from various disciplines, helping them understand how instrumentation and controls provide layers of protection for basic process control systems, ultimately increasing overall system reliability. Plant Hazard Analysis and Safety Instrumentation Systems will also be a great guide for researchers, students, and graduate level professionals in process safety disciplines, Electrical and Industrial Engineers specializing in safety and area classifications, as well as plant managers and engineers in the industry.
1. 1 Introduction - p. 1 2. 2 Hazard and risk - p. 7 3. 3 Risk register, risk matrix and risk ranking - p. 14 4. 4 Consequence, PHA and ALARP - p. 30 5. 5 Basics of mathematics - p. 44 6. 6 Fault tolerence and plant aging - p. 53 7. 7 Safety instrumentation - p. 60 8. 7.1 Commonly used terms - p. 62 9. 7.2 Control objective and layers of protections - p. 64 10. 7.3 SIS boundary and layout - p. 65 11. 7.4 SIS related issues - p. 65 12. 8 Functional safety and safety integrity level (SIL) - p. 69 13. 8.1 Normally used terms - p. 70 14. 8.2 Functional safety discussions - p. 71 15. 8.3 Safety and safety integrity level - p. 72 16. References - p. 73 17. Further reading - p. 74 18. 2 Evaluation of hazard and risk analysis - p. 77 19. Abstract - p. 77 20. 1 Plant hazard analysis preliminaries - p. 75 21. 2 Evaluation of plant hazard selection techniques - p. 86 22. 3 Hazard identification (HAZID) & risk estimate - p. 101 23. 4 Risk assessment and management - p. 126 24. 5 Control measure - p. 142 25. 5.1 Safety management system - p. 149 26. 6 Conclusion - p. 150 27. References - p. 152 28. Further reading - p. 152 29. 3 Qualitative hazard analysis - p. 155 30. 4 Guided word hazard analysis - p. 185 31. Abstract - p. 185 32. 1 HAZOP study/analysis - p. 187 33. 2 Failure mode and effect analysis - p. 232 34. 2.3 Controls and recommended actions - p. 255 35. 2.4 FMEA/FMECA worksheet - p. 257 36. 2.5 FMEA FOR E/E/PES - p. 259 37. 2.6 Automated FMEA (the concepts) - p. 270 38. References - p. 277 39. Further reading - p. 278 40. 5 Quantitative hazard analysis - p. 282 41. Abstract - p. 282 42. 1 Introduction - p. 281 43. 2 Event tree analysis - p. 285 44. 3 Fault tree analysis - p. 299 45. 4 Layer of protection analysis (LOPA) - p. 324 46. 5 Quantitative risk analysis (QRA)—In brief - p. 347 47. 6 Human reliability analysis (HRA)—In brief - p. 350 48. References - p. 355 49. Further reading - p. 355 50. 6 Discussions on standards for RA & SIS - p. 360 51. Abstract - p. 360 52. 1 Standard requirements for risk assessment - p. 359 53. 2 Short discussions on standards for PHA(s) - p. 371 54. 3 Batch controls and associated standard(s) - p. 377 55. 4 Functional safety standard(s): IEC 61508 - p. 393 56. 5 Functional safety process standard(s): IEC 61511 - p. 412 57. 5.3 IEC 61511-1 (SW part only) - p. 422 58. 5.4 IEC 61511 discussions - p. 428 59. 6 Functional safety standard: ANSI/ISA-84.00.01 - p. 428 60. 7 Functional safety standard: ISO 26262 - p. 431 61. 7.1 Basics of ISO 26262 - p. 431 62. 7.2 Parts of ISO 26262 - p. 431 63. 7.3 Phases of ISO 26262 - p. 432 64. 7.4 ISO 26262 lifecycle and difference with IEC 61508 - p. 432 65. 7.5 ISO 26262: Automotive safety integrity level - p. 432 66. References - p. 434 67. Further reading - p. 435 68. 7 Safety instrumentation functions and systems (including FGS) - p. 437 69. Abstract - p. 437 70. 1 SIF SIS & SIL discussions - p. 437 71. 2 FMEDA and system integration issues - p. 482 72. 3 Fire and gas system in SIS - p. 486 73. 3.3 Performance based FGS—Discussions - p. 497 74. 4 Role of alarm system in SIS - p. 506 75. References - p. 507 76. Further reading - p. 508 77. 8 SIL, PE, FGS and plant emergencies - p. 511 78. Abstract - p. 511 79. 1 SIL methods - p. 511 80. 2 SIL policy and programmable systems - p. 542 81. 3 Fire and gas - p. 564 82. 3.1 FGS model and detection coverage - p. 565 83. 3.2 Gas detection discussions - p. 567 84. 3.3 Combustible gases - p. 568 85. 3.4 Toxic gases - p. 569 86. 3.5 Oxygen deficiency/enrichment - p. 569 87. 3.6 Gas detector placements - p. 570 88. 4 Plant emergencies - p. 571 89. 4.1 ESD fundamentals - p. 572 90. 4.2 Instrument quality air - p. 573 91. 4.3 Performance requirements - p. 574 92. 4.4 Reliability issues - p. 574 93. 4.5 Protection issues - p. 575 94. 4.6 ESD configuration & HMI - p. 575 95. References - p. 577 96. Further reading - p. 578 97. 9 SIS requirements for fieldbus and control components - p. 581 98. Abstract - p. 581 99. 1 General - p. 581 100. 2 Safe fieldbus system [1] - p. 590 101. 3 Field sensors for SIS - p. 601 102. 4 Alarm systems in SIS - p. 609 103. 5 SIS logic solver - p. 628 104. 6 Final control elements for SIS - p. 639 105. 6.1 Various possible valve configurations in SIS - p. 643 106. 6.2 Testing of movement for shutdown valve - p. 644 107. 6.3 Smart/intelligent digital positioner - p. 648 108. References - p. 649 109. Further reading - p. 650 110. 10 Instrumentation safety implementation and explosion protection - p. 653 111. Abstract - p. 653 112. Explanation - p. 653 113. Section I: IEC 61508/61511 implementation - p. 656 114. 1 Safety requirement specification - p. 657 115. 2 Certification and proof testing - p. 681 116. 3 Hazardous area classification and electrical safety - p. 692 117. 3.5 Explosion protection - p. 719 118. 3.6 Enclosure class - p. 721 119. 3.7 Intrinsic safety - p. 726 120. References - p. 751 121. Further reading - p. 752 122. 11 Fault tolerance, protection layer and system security - p. 755 123. 12 Discussions on industrial application of SIS - p. 819 124. 13 Safety issues in wireless systems (WSN & CIP) - p. 870 125. 14 Safety in Industrie 4.0 and digital transformation - p. 909 126. Appendix I: Popular terms and their definitions - p. 939 127. Appendix II: Electrical protection and enclosure class - p. 945 128. Appendix III: Simplified mathematical equations - p. 967 129. Appendix IV: Little-JIL process language - p. 977 130. Appendix V: Embedded control - p. 991 131. Appendix VI: Cost impact discussion - p. 1017 132. Index - p. 1031
Plant Hazard Analysis and Safety Instrumentation Systems serves as a comprehensive guide to the development of safety instrumented system (SIS), outlining the connections between SIS requirements, process hazard analysis, SIS lifecycle, implementation, safety analysis, and realization in control systems. The book also explores the impact of recent advances, such as SIL, SIS, and Fault Tolerance. In line with technological developments, it covers safety in wireless systems as well as in Industrie 4.0 and Digital Transformation.
Plant Hazard Analysis and Safety Instrumentation Systems incorporates practical examples throughout the book. It covers safety analysis and realization in control systems, providing up-to-date descriptions of modern concepts like SIL, SIS, and SIF. The inclusion of security issues alongside safety issues is particularly relevant for the programmable systems used in modern plant instrumentation systems. The new chapters in this updated edition address security concerns
crucial for programmable systems in modern plants- including topics such as discussion of hazardous atmospheres and their impact on electrical enclosures, the use of IS circuits, and their links to safety considerations in major developmental areas, including IIoT, Cloud computing, wireless safety, Industry 4.0, and digital transformation.
This book is a valuable resource for Process Control Engineers, Process Engineers, Instrumentation Engineers, Safety Engineers, and Mechanical/Manufacturing Engineers from various disciplines, helping them understand how instrumentation and controls provide layers of protection for basic process control systems, ultimately increasing overall system reliability. Plant Hazard Analysis and Safety Instrumentation Systems will also be a great guide for researchers, students, and graduate level professionals in process safety disciplines, Electrical and Industrial Engineers specializing in safety and area classifications, as well as plant managers and engineers in the industry.
1. 1 Introduction - p. 1 2. 2 Hazard and risk - p. 7 3. 3 Risk register, risk matrix and risk ranking - p. 14 4. 4 Consequence, PHA and ALARP - p. 30 5. 5 Basics of mathematics - p. 44 6. 6 Fault tolerence and plant aging - p. 53 7. 7 Safety instrumentation - p. 60 8. 7.1 Commonly used terms - p. 62 9. 7.2 Control objective and layers of protections - p. 64 10. 7.3 SIS boundary and layout - p. 65 11. 7.4 SIS related issues - p. 65 12. 8 Functional safety and safety integrity level (SIL) - p. 69 13. 8.1 Normally used terms - p. 70 14. 8.2 Functional safety discussions - p. 71 15. 8.3 Safety and safety integrity level - p. 72 16. References - p. 73 17. Further reading - p. 74 18. 2 Evaluation of hazard and risk analysis - p. 77 19. Abstract - p. 77 20. 1 Plant hazard analysis preliminaries - p. 75 21. 2 Evaluation of plant hazard selection techniques - p. 86 22. 3 Hazard identification (HAZID) & risk estimate - p. 101 23. 4 Risk assessment and management - p. 126 24. 5 Control measure - p. 142 25. 5.1 Safety management system - p. 149 26. 6 Conclusion - p. 150 27. References - p. 152 28. Further reading - p. 152 29. 3 Qualitative hazard analysis - p. 155 30. 4 Guided word hazard analysis - p. 185 31. Abstract - p. 185 32. 1 HAZOP study/analysis - p. 187 33. 2 Failure mode and effect analysis - p. 232 34. 2.3 Controls and recommended actions - p. 255 35. 2.4 FMEA/FMECA worksheet - p. 257 36. 2.5 FMEA FOR E/E/PES - p. 259 37. 2.6 Automated FMEA (the concepts) - p. 270 38. References - p. 277 39. Further reading - p. 278 40. 5 Quantitative hazard analysis - p. 282 41. Abstract - p. 282 42. 1 Introduction - p. 281 43. 2 Event tree analysis - p. 285 44. 3 Fault tree analysis - p. 299 45. 4 Layer of protection analysis (LOPA) - p. 324 46. 5 Quantitative risk analysis (QRA)—In brief - p. 347 47. 6 Human reliability analysis (HRA)—In brief - p. 350 48. References - p. 355 49. Further reading - p. 355 50. 6 Discussions on standards for RA & SIS - p. 360 51. Abstract - p. 360 52. 1 Standard requirements for risk assessment - p. 359 53. 2 Short discussions on standards for PHA(s) - p. 371 54. 3 Batch controls and associated standard(s) - p. 377 55. 4 Functional safety standard(s): IEC 61508 - p. 393 56. 5 Functional safety process standard(s): IEC 61511 - p. 412 57. 5.3 IEC 61511-1 (SW part only) - p. 422 58. 5.4 IEC 61511 discussions - p. 428 59. 6 Functional safety standard: ANSI/ISA-84.00.01 - p. 428 60. 7 Functional safety standard: ISO 26262 - p. 431 61. 7.1 Basics of ISO 26262 - p. 431 62. 7.2 Parts of ISO 26262 - p. 431 63. 7.3 Phases of ISO 26262 - p. 432 64. 7.4 ISO 26262 lifecycle and difference with IEC 61508 - p. 432 65. 7.5 ISO 26262: Automotive safety integrity level - p. 432 66. References - p. 434 67. Further reading - p. 435 68. 7 Safety instrumentation functions and systems (including FGS) - p. 437 69. Abstract - p. 437 70. 1 SIF SIS & SIL discussions - p. 437 71. 2 FMEDA and system integration issues - p. 482 72. 3 Fire and gas system in SIS - p. 486 73. 3.3 Performance based FGS—Discussions - p. 497 74. 4 Role of alarm system in SIS - p. 506 75. References - p. 507 76. Further reading - p. 508 77. 8 SIL, PE, FGS and plant emergencies - p. 511 78. Abstract - p. 511 79. 1 SIL methods - p. 511 80. 2 SIL policy and programmable systems - p. 542 81. 3 Fire and gas - p. 564 82. 3.1 FGS model and detection coverage - p. 565 83. 3.2 Gas detection discussions - p. 567 84. 3.3 Combustible gases - p. 568 85. 3.4 Toxic gases - p. 569 86. 3.5 Oxygen deficiency/enrichment - p. 569 87. 3.6 Gas detector placements - p. 570 88. 4 Plant emergencies - p. 571 89. 4.1 ESD fundamentals - p. 572 90. 4.2 Instrument quality air - p. 573 91. 4.3 Performance requirements - p. 574 92. 4.4 Reliability issues - p. 574 93. 4.5 Protection issues - p. 575 94. 4.6 ESD configuration & HMI - p. 575 95. References - p. 577 96. Further reading - p. 578 97. 9 SIS requirements for fieldbus and control components - p. 581 98. Abstract - p. 581 99. 1 General - p. 581 100. 2 Safe fieldbus system [1] - p. 590 101. 3 Field sensors for SIS - p. 601 102. 4 Alarm systems in SIS - p. 609 103. 5 SIS logic solver - p. 628 104. 6 Final control elements for SIS - p. 639 105. 6.1 Various possible valve configurations in SIS - p. 643 106. 6.2 Testing of movement for shutdown valve - p. 644 107. 6.3 Smart/intelligent digital positioner - p. 648 108. References - p. 649 109. Further reading - p. 650 110. 10 Instrumentation safety implementation and explosion protection - p. 653 111. Abstract - p. 653 112. Explanation - p. 653 113. Section I: IEC 61508/61511 implementation - p. 656 114. 1 Safety requirement specification - p. 657 115. 2 Certification and proof testing - p. 681 116. 3 Hazardous area classification and electrical safety - p. 692 117. 3.5 Explosion protection - p. 719 118. 3.6 Enclosure class - p. 721 119. 3.7 Intrinsic safety - p. 726 120. References - p. 751 121. Further reading - p. 752 122. 11 Fault tolerance, protection layer and system security - p. 755 123. 12 Discussions on industrial application of SIS - p. 819 124. 13 Safety issues in wireless systems (WSN & CIP) - p. 870 125. 14 Safety in Industrie 4.0 and digital transformation - p. 909 126. Appendix I: Popular terms and their definitions - p. 939 127. Appendix II: Electrical protection and enclosure class - p. 945 128. Appendix III: Simplified mathematical equations - p. 967 129. Appendix IV: Little-JIL process language - p. 977 130. Appendix V: Embedded control - p. 991 131. Appendix VI: Cost impact discussion - p. 1017 132. Index - p. 1031
