Unit Name

SAFETY SYSTEMS

Unit Code

ME508

Unit Duration

12 weeks

Award

Graduate Diploma of Engineering (Industrial Automation) Duration: 1 year

Master of Engineering (Industrial Automation) Duration: 2 years

Year Level

1st

Unit Creator/Reviewer

Dr. Srinivas Shastri

Core/Elective

Core

Pre/Co-requisites

ME502 Programmable Logic Controllers ME503 Industrial Process Control Systems ME504 Industrial Instrumentation

Credit Points

3

Grad Dip total course credit points = 24 (3 credits x 8 (units))

Masters total course credit points = 48

(3 credits x 12 (units) + 12 credits (Thesis))

Mode of Delivery

On-Campus or Online

Unit Workload

10 hours per week: Lecture - 1 hour

Tutorial Lecture - 1 hours

Practical / Lab - 1 hour (where applicable)

Personal Study recommended - 7 hours (guided and unguided)

Unit Description and General Aims

This subject provides the fundament concept of functional safety systems to reduce the likelihood of a serious hazardous event in an industrial process plant. In this subject the student will be introduced to a common safety philosophy of hazard identification, risk management and risk based design of protection methods. A series of topics will prepare the student for a practical and challenging application project typical of those currently seen in large chemical processing plants.

Learning Outcomes

On successful completion of this subject/unit, students are expected to be able to:

  1. Specify and design instrumentation systems suitable for installation in classified hazardous areas and in accordance with internationally recognized standards. Bloom’s Level 5

  2. Plan and execute a safety control systems project in accordance with the safety life cycle requirements of internationally recognized standards.

    Bloom’s Level 5

  3. Participate in and make a valuable contribution to any HAZOP study workshop.

    Bloom’s Level 5

  4. Evaluate cost effective safety system solutions for hazardous processes and justify the investment to the operating company.

    Bloom’s Level 6

  5. Develop training and competency growth programmes to enable a company to comply with the functional safety management requirements of internationally recognized standards.

Bloom’s Level 5

Bloom’s Taxonomy

The cognitive domain levels of Bloom’s Taxonomy:

Bloom’s

Level

Bloom’s

Category

Description

1

Knowledge

Recall, define and list facts, concepts, methods, terminologies, theories and structures.

2

Comprehension

Demonstrate understanding by comparing, organizing, describing, translating, interpreting, paraphrasing, explaining and distinguishing.

3

Application

Use knowledge to solve problems, identify connections and show relationships, in context.

4

Analysis

Examine information, breakdown a problem, determine relationships and causes, make inferences, classify and infer from evidence.

5

Synthesis

Produce a pattern from relationships, propose operations, formulate a design, compose a hypothesis, reassemble information, construct, plan, invent, predict

and create.

6

Evaluation

Make judgements based on evidence and external criteria, determine best practice, optimise, validate ideas, judge and critique, assess, valuate and make recommendations.

Engineers Australia

The Australian Engineering Stage 1 Competency Standards for the Professional Engineer, approved as of 2013. This table is referenced in the mapping of graduate attributes to learning outcomes and via the learning outcomes to student assessment.

Stage 1 Competencies and Elements of Competency

1.

Knowledge and Skill Base

1.1

Comprehensive, theory based understanding of the underpinning natural and physical sciences and the engineering fundamentals applicable to the engineering discipline.

1.2

Conceptual understanding of the mathematics, numerical analysis, statistics, and computer and information sciences which underpin the engineering discipline.

1.3

In-depth understanding of specialist bodies of knowledge within the engineering discipline.

1.4

Discernment of knowledge development and research directions within the engineering discipline.

1.5

Knowledge of engineering design practice and contextual factors impacting the engineering discipline.

1.6

Understanding of the scope, principles, norms, accountabilities and bounds of sustainable engineering practice in the specific discipline.

2.

Engineering Application Ability

2.1

Application of established engineering methods to complex engineering problem solving.

2.2

Fluent application of engineering techniques, tools and resources.

2.3

Application of systematic engineering synthesis and design processes.

2.4

Application of systematic approaches to the conduct and management of engineering projects.

3.

Professional and Personal Attributes

3.1

Ethical conduct and professional accountability.

3.2

Effective oral and written communication in professional and lay domains.

3.3

Creative, innovative and pro-active demeanour.

3.4

Professional use and management of information.

3.5

Orderly management of self, and professional conduct.

3.6

Effective team membership and team leadership.

Graduate Attributes

Successfully completing this Unit will contribute to the recognition of attainment of the following graduate attributes aligned to the AQF Level 9 criteria, Engineers Australia Stage 1 Competency Standards for the Professional Engineer and the Washington Accord and the Program Level Outcomes (PLO):

Graduate Attributes / Program Level Outcomes (Knowledge, Skills, Abilities, Professional and Personal Development)

EA Stage 1 Competencies

Learning Outcomes

A. Effective Communication (PLO 1)

A1. Cognitive and technical skills to investigate, analyse and organise information and ideas and to communicate those ideas clearly and fluently, in both written and spoken forms appropriate to the audience.

2.2, 3.2

3

A2. Ability to professionally manage oneself, teams, information and projects and engage effectively and appropriately across a diverse range of international cultures in leadership, team and individual roles.

2.4, 3.2, 3.4,

3.5, 3.6

3

B. Critical Judgement (PLO 2)

B1. Ability to critically analyse and evaluate complex information and theoretical concepts.

1.1, 1.2, 1.3,

2.1

2

B2. Ability to creatively, proactively and innovatively apply theoretical concepts, knowledge and approaches with a high level of accountability, in an engineering context.

1.5, 2.1, 3.3,

3.4

2

C. Design and Problem Solving Skills (PLO 3)

C1. Cognitive skills to synthesise, evaluate and use information from a broad range of sources to effectively identify, formulate and solve engineering problems.

1.5, 2.1, 2.3

1, 4, 5

C2. Technical and communication skills to design complex systems and solutions in line with developments in engineering professional practice.

2.2, 2.3

1, 2, 5

C3. Comprehension of the role of technology in society and identified issues in applying engineering technology ethics and impacts; economic; social; environmental and sustainability.

1.5, 1.6, 3.1

4, 5

D. Science and Engineering Fundamentals (PLO 4)

D1. Breadth and depth of mathematics, science, computer technology and specialist engineering knowledge and understanding of future developments.

1.1, 1.2, 1.3,

1.4

1, 2, 5

D2. Knowledge of ethical standards in relation to professional engineering practice and research.

1.6, 3.1, 3.5

1, 2, 5

D3. Knowledge of international perspectives in engineering and ability to apply various national and International Standards.

1.5, 1.6, 2.4,

3.4

1, 2, 5

E. Information and Research Skills (PLO 5)

E1. Application of advanced research and planning skills to engineering projects.

1.4, 2.4, 3.6

4, 5

E2. Knowledge of research principles and methods in an engineering context.

1.4, 1.6

5

Unit Content and Learning Outcomes to Program Level Outcomes (PLO) via Bloom’s Taxonomy Level

This table details the mapping of the unit content and unit learning outcomes to the PLOs and graduate attributes at the corresponding Bloom’s Taxonomy level, specified by the number in the table.

 

Integrated Specification /

Program Learning Outcomes

PLO 1

PLO 2

PLO 3

PLO 4

PLO 5

Unit Learning Outcomes

LO1

-

-

5

5

-

LO2

-

5

5

5

-

LO3

5

-

-

-

-

LO4

-

-

6

-

6

LO5

-

-

5

5

5

Unit Study

Assessments

5

5

6

5

6

Lectures/Tutorials

5

5

6

5

6

 

Max Bloom’s level

5

5

6

5

6

Total PLO coverage

3

3

6

5

4

Student assessment

Assessment Type

(e.g. Assignment - 2000 word essay (specify topic) Examination (specify length and format))

When assessed (e.g. Week 5)

Weighting (% of total unit marks)

Learning Outcomes Assessed

Assignment 1

Type: Multi-choice test / Group work / Short answer questions / Role Play / Self-Assessment / Presentation

Example Topic: Short questions on Area Classification Diagram, Electrical Protection Solutions & control and process failure mode analysis

Week 5

15%

1, 2

Assignment 2

Type: Report / Group work / Short answer questions / Case study

Example Topic: Short questions on SIS calculations & SIL determination study

Week 7

15%

4, 5

Assignment 3

Type: Report / Research / Paper / Case Study / Site Visit / Problem analysis / Project / Professional recommendation

Example Topic: HAZOP study and report by teams

Week 9

20%

3

Assignment 4

Type: Report / Research / Paper / Case Study / Site Visit / Problem analysis / Project / Professional recommendation

Example Topic: SIS Project solution by teams

Final Week

30%

1, 2, 3, 4, 5

Practical Participation

Example: May be in the form of quizzes, class tests, practical assessments, remote labs, simulation software or case studies

Continuous

15%

1, 2, 3, 4, 5

Attendance / Tutorial Participation

Example: Presentation, discussion, group work, exercises, self-assessment/reflection, case study analysis, application.

Continuous

5%

1, 2, 3, 4, 5

Prescribed and recommended readings

Required textbook

  • Safety Instrumented Systems: design analysis and justification: Paul Gruhn and Harry Cheddie. 2nd edition 2006. ISBN 1-55617-956-1 ISA, Research Triangle Park NC 27709 USA.

Reference Materials

Number of peer-reviewed journals and websites (advised during lectures). Some examples are listed below.

  1. Engineering standard: IEC 61511 Functional Safety - Safety instrumented systems for the process industry sector. Parts 1 and 3. 2002. (alternatively AS 61511 or BS EN 61511 or ANSI/ISA S84.01:2004 )

  2. Engineering guide: IEC 61882: Hazard and Operability Studies (HAZOP studies) - Application Guide. 1st edition 2001-05

  3. Engineering standard: IEC 60079 Explosive Atmospheres. Part 14: Terminologies and principles

  4. HAZOP Guide to Best Practice: by Frank Crawley, Malcolm Preston and Brian Tyler. (ISBN0-85295-427-1) Published in 2000 and reprinted 2002.

  5. HAZOP and HAZAN by Trevor Kletz 4th edition. 1999 I Chem. Eng Rugby, UK

  6. IDC notes and Reference texts as advised.

  7. Other material advised during the lectures

Unit Content:

One topic is delivered per contact week, with the exception of part-time 24-week units, where one topic is delivered every two weeks.

Topic 1

Introduction to Safety Classifications

  1. Safety management principles

  2. Principles and classification of flammable atmospheres

  3. Engineering standard IEC 60079 for hazardous atmosphere practices

Topic 2

HAZOP Study

  1. Hazard identification in automated plants

  2. Hazard and Operability Study (HAZOP) method

  3. HAZOP leadership

  4. Worksheet reporting using Excel

Topic 3

Electrical Protection Methods

  1. Protection methods including intrinsically safe field bus concepts

  2. Maintenance and competency requirements for Ex systems

Topic 4

Control and Failure Mode Analysis

  1. Hazard analysis methods and LOPA modelling

  2. A brief study of a process hazard situation with fault tree analysis

  3. Layer of protection analysis model development using Excel formatted software

Topic 5

Safety Systems

  1. Overview of Safety Instrumented Systems (SIS)

  2. Management of functional safety

  3. Safety life cycle as per IEC 61511

Topic 6

Safety Integrity Level Determination

  1. Safety Integrity Level (SIL) determination: application examples in group study

  2. Development of the Safety Requirements Specification: application example

Topic 7

Safety Instrumented Systems

  1. SIS configuration and equipment selection.

  2. Principles of safety certified PLCs

  3. Principles of high integrity application software

Topics 8 and 9

SIS Performance Evaluation

  1. SIS Performance evaluation and reliability modelling

  2. Calculation practical and development of Excel spread sheet tool

  3. Validation, testing and maintenance of SIS installations

Topics 10, 11 and 12

SIS Project

  1. SIS Project launch meeting

  2. SIS project consultations

  3. SIS project preparations

  4. Assignment reviews

  5. SIS project presentations and assessments