Unit Name

Process Safety Lifecycle Management

Unit Code

MOG506

Unit Duration

12 weeks

Award

Graduate Diploma of Engineering (Electrical and Instrumentation in Oil and Gas)

Duration: 1 year

Master of Engineering (Electrical and Instrumentation in Oil and Gas) Duration: 2 years

Year Level

One

Unit Coordinator

Fraser Maywood

Core/Elective

Core

Pre/Co-requisites

Nil

Credit Points

3

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

Masters total course credit points = 48

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

Mode of Delivery

Combination of modes: Online synchronous lectures; asynchronous discussion groups, videos, remote and cloud-based labs (simulations); web and video conferencing tutorials. High emphasis on personal and group self-study.

Delivery/ Contact Hours per week

Student workload including “contact hours” = 10 hours per week: Lecture 1 hour

Tutorial Lecture 1 hours

Practical / Lab 1 hour (where relevant) Personal Study recommended - 7 hours

Resource Requirements Software

Web & Video conferencing software

Students will be provided with Blackboard Collaborate (or similar) for video and web conferencing. This will allow them to attend lectures, interact with lecturers and fellow students, and use the Remote Lab facility. Students will be required to download the latest version of Java and .NET in order to use these packages.

Skype

For ease of communicating with peers and lecturers, installation of this package is recommended.

Word, PowerPoint and Excel

It is recommended that students install at least a 2007 version of the Microsoft Office. Older versions will work, but sometimes create issues with file compatibility. If individuals are reluctant to use these, they can also use Open Office (www.openoffice.org).

Virus detection

As students are co-operating with people from throughout the world with a multitude of different PCs, it is recommended that they have good quality up-to-date virus detection software installed. The free version of AVG is sufficient. A thorough automated scan of computers at least once a week is recommended.

Learning Management System

EIT uses a state-of-the-art learning management system (Moodle) for lecturing and interacting with lecturers and fellow students. Students can chat, socialize, and collaborate on projects with similarly motivated and enthusiastic course participants.

Computing resource requirements

Computer

Students’ computers should have an Intel Core Duo CPU and 2 Gigabytes of RAM. Hard disk space available should be at least 2 Gigabytes free. If necessary the built-in hard drive can be augmented with an inexpensive USB drive. No particular special graphics card is required. The operating system should be Windows with Windows 7 Service Pack 1 as a minimum.

Internet

An ADSL Internet connection with a minimum speed of 128 kbps down and 64 kbps up is recommended.

Good quality headset and low cost web cam

Students will require a good quality stereo headset with analogue or USB connectors. In addition, a low-cost USB webcam is recommended. Students should budget in the order of

$30 for a headset and $20 for a webcam. This will vary from country to country.

Technical Help

For difficulties with other online materials the lecturer should be contacted. Technical material will be accessible 24/7 through the online portal.

Unit Description and General Aims

This unit provides sufficient depth of understanding of the principles and practical application of functional safety from initial hazard identification through design, configuration, testing, installation, commissioning and maintenance of a safety control system and associated instrumentation in the context of the oil and gas industry.

The unit will concentrate on functional safety and safety instrumented systems (SIS) used in the industry in the broader context of overall process safety. The aim is to ensure participants gain a wider understanding and thus are better placed to provide balanced practical advice on achieving process safety through the application of instrumented safety.

The underlying principles of process safety (hazard identification, risk assessment, layers of protection analysis) and functional safety lifecycle (FSLC) activities will provide the student with an understanding of how to systematically identify and apply these principles to SIS used in industry (eg package plant machinery protection, process / emergency shutdown systems, fire and gas system design). Practical aspects of the FSLC development and overall functional safety management will be addressed, including operation and maintenance activities.

Learning Outcomes

On successful completion of this Unit, students are expected to be able to:

  1. Identify principles of process safety to onshore and offshore oil & gas facilities including industry regulatory and standards requirements and common hazard management processes and techniques.

  2. Identify and apply principles of FSLC management in accordance with IEC 61511 (and IEC 61508) to SIS used on onshore and offshore oil & gas facilities.

  3. Analyse and apply sound engineering practices and demonstrate in-depth understanding of individual functional safety lifecycle activities.

    Professional Development

    Completing this unit will add to students professional development/competencies by:

    1. Fostering the personal and professional skills development of students to:

      1. Be adaptable and capable 21st century citizens, who can communicate effectively, work collaboratively, think critically and innovatively solve complex problems.

      2. Equipping individuals with an increased capacity for lifelong learning and professional development.

      3. Planning and organising self and others

      4. Instilling leadership qualities and a capacity for ethical and professional contextualization of knowledge

    2. Enhancing students’ investigatory and research capabilities through:

      1. Solving complex and open-ended engineering problems

      2. Accessing, evaluating and analysing information

      3. Processes and procedures, cause – effect investigations

    3. Developing the engineering application abilities of students through:

      1. Assignments

      2. Labs / practical / case studies / self-study (where applicable)

Graduate Attributes

Successfully completing this Unit will contribute to the recognition of attainment of the following graduate attributes.

A. Effective Communication

Learning Outcomes (Refer to 2.2)

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.

1,2,3

A2. Ability to engage effectively and appropriately across a diverse range of international cultures.

A, 1

B. Critical Judgement

 

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

1,2,3, B

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

1,2,3,A

C. Design and Problem Solving Skills

 

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

2,3

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

2,3

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

 

D. Science and Engineering Fundamentals

 

D1. Breadth and depth of knowledge of engineering and understanding of future developments.

1,B

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

A

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

B, C

E. Information and Research Skills

 

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

1,2,3, A, B

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

1,2,3, B

Student assessment

Assessment Type

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

When assessed (eg Week 5)

Weighting (% of total unit marks)

Learning Outcomes Assessed

Assessment 1 Type: Quiz Word length: n/a

Topic examples: Fundamental concepts of process safety

Week 5

20%

1, 2

Assessment 2

Type: Report (Midterm Project)

[This will include a progress report; literature review, hypothesis, and proposed solution with concept workings]

Word length: 1000

Topic examples: Safety requirement specification for an offshore production facility for a SIS or as specified by the lecturer.

Week 8

25%

1, 2, 3

Assessment 3

Type: Report (Final Project)

[If a continuation of the midterm, this should complete the report by adding sections on: workings, implementation, results, verification/validation, conclusion/challenges and recommendations/future work. If this is a new report, all headings from the midterm and the final reports must be included.]

Word length: 4000

Topic examples: Functional safety management plan development

Week 12

35%

1, 2, 3,

Practical Participation

May be in the form of quizzes, class tests, practical assessments, remote labs, simulation software or case studies: E.g. Safety instrumented function design verification calculations for several SIFs (including optimisation based on actual maintenance data gathered) or as directed by the lecturer

Continuous

15%

3

Attendance

Continuous

5%

1-3

Prescribed and recommended readings

Required textbook(s)

  • T. A. Kletz, Process Plants - A Handbook for Inherently Safer Design, Taylor and Francis, London, 1998. ISBN 978-1-56032-619-9

    Reference Materials

  • Functional safety of electrical/electronic/programmable electronic safety-related systems, IEC standard 61508-1 to 7,

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

  • ISO14121-2 Practical examples of Risk Assessments

  • AS 4024 Safety of Machinery Standard

  • EEMUA Publication 222 Guide to the application of IEC 61511 to safety instrumented systems in the UK process industries.

  • ISA TR84.00.02 (various parts as selected by course developer / lecturer) on further Guidance on the application of IEC 61511 to safety instrumented systems, 2010, International Society for Automation (ISA)

  • D.J. Smith and K.G.L. Simpson, Safety critical systems handbook: a straightforward guide to functional safety: IEC 61508 (2010 edition) and related standards, 2010

  • Layer of Protection Analysis: Simplified Process Risk Assessment (A CCPS Concept Book)

  • W.M. Goble and H. Cheddie, Safety Instrumented Systems Verification: Practical Probabilistic Calculations, 2010

  • Number of peer-reviewed journals and websites (advised during lectures) [some examples below]:

    • Control Engineering

    • EIT notes

Weekly Content:

Week 1 and 2

Process Safety Overview

  1. What goes wrong and why

  2. Hazard identification, risk assessment

  3. Safety maturity model, ALARP and tolerable risk

  4. System safety vs. safety management system

  5. System safety process

  6. Systematic failure avoidance: Quality control, design codes, Preventative maintenance (RBI, RCM), etc.

  7. Random hardware failure, failure modes (including unrevealed unsafe failures), average probability of failure on demand, test intervals and coverage (Random failure avoidance: redundancy, diagnostics, etc.)

  8. Hazard reduction and layers of protection

  9. Risk evaluation models – qualitative vs. quantitative, deterministic vs. stochastic, probabilistic, risk analysis model, developing accident scenarios and initiating events, event trees, risk profiles, consequence determination, uncertainty

  10. Risk analysis techniques (process safety analysis, cause and consequence analysis, root cause analysis, bow-tie analysis

  11. Advantages and dis-advantages of SIL/LOPA studies

  12. Organisational safety culture

  13. Current state of process safety and key challenges

Week 3

Legislative and Compliance Framework

  1. Typical legislative requirements

  2. US OSHA PSM Regulation

  3. US EPA / RMP Regulations

  4. European Union – Seveso I, II, and III, REACH

  5. UK COMAH / CIMAH

  6. Norway / North Sea (Safety Case)

  7. Australia / New Zealand (Major Hazard Facilities)

  8. Australia NOPSEMA (Safety Case)

  9. Codes and standards

  10. Safety critical elements and performance standards

Weeks 4 and 5

IEC 61511 (and IEC 61508) Overview

  1. Background to the standard

  2. Process risk, residual risk, tolerable risk

  3. Separation of process control and process safety

  4. Equipment Under Control (EUC) and its application, detection, logic action and safe state definition

  5. Safety functions and safety-related systems

  6. Safety integrity levels (high and low demand)

  7. Systematic capability (refer IEC 61508)

  8. Different voting arrangements and their consequences

  9. SIL levels, device types and architectural constraints: fault tolerance /redundancy – differences between IEC 61511 and IEC 61508

  10. IEC 61511 Clauses 5 and 10.3

  11. Safety software requirements – dedicated SRS, V-Model

  12. Avoidance of systematic failures and spurious trips

  13. Functional safety assessments

  14. Functional safety management overview (including planning, verification, validation, functional safety assessment, function testing, management of change, competency and certification) – differences between project personnel and end-user

  15. Application of functional safety to Oil & Gas industry and special applications: High Integrity Pressure Protection Systems, Burner Management Systems (ie sequential logic), drilling equipment, batch processes, fire and gas

  16. Legacy issues and ‘proven in use’ solutions

Week 6

SIL Studies

  1. When to conduct SIL studies in relation to other safety studies and level of design maturity

  2. Key inputs: risk criteria analysis: calibrating company risk matrices for SIL studies, safety instrumented function identification, HAZAN / HAZOP studies, project documentation

  3. Attendees

  4. Assumptions (eg generally semi-quantitative technique used)

  5. Conducting the workshop

  6. Reporting

  7. Independent review

  8. Re-analysis during operations

Week 7

Safety Instrumented Function Design and Verification

  1. Identifying SIF elements and safe state

  2. Reliability block diagrams and fault modelling (FTA, Markov modeling, simplified equations)

  3. Failure modes, diagnostic coverage, safe failure fraction, failure data sources & assumptions

  4. Proven in use assessment

  5. Proof test coverage, preventative maintenance requirements

  6. Redundancy and common mode failure

  7. Tools and techniques

  8. Probability failure on demand calculations examples

Week 8

Safety Requirements Specification

  1. Separation of SIF and non-SIF

  2. SIL determination output and summary

  3. Project functional requirements

  4. Design basis; scope, context, assumptions, clarifications, definitions etc.

  5. SIF characterisation details including: Description, Instances, P&ID, SAFE Chart, Case, Hazardous Event, Causes, Consequences, Process Safety State, Other LOPs Considered, Target SIL, Risk Reduction Factor, Safety-Critical, Demand Mode, Proof Test Interval, MTTFSP, MTTR, Other Special Considerations.

Week 9

Detailed Design Considerations

  1. Hardware

    • Selection of the logic solver hardware supplier for the SIS, required components and architecture

    • Selection of field devices and other components of the SIS

    • I/O allocation

    • Definition of third party interfaces (including HMI)

    • Calculations (power consumption, heat dissipation, fault current, cable sizing, etc.)

    • Prototype testing of typical loops

    • Production of drawings to enable system to be built

    • Production of documents and drawings to enable the system to be installed

  2. Software

    • Development of project Software Quality Plan

    • Selection of software tools and programming language

    • Detailed software design (including definition of program structure, required software modules, communication drivers, diagnostics usage, alarm handling, voting arrangements, overrides, interfaces, etc)

Week 10

Functional Safety Management

  1. Planning – division of responsibility across the safety lifecycle, typical documentation suite

  2. FSM plan covering concept, strategy, scope, activities, competency, personnel, roles and responsibilities, organisation, independence, processes (ISO 9000 type and FSM specific), planning, documentation, verification and validation plans, monitoring, review and audits

  3. Guidance on specific elements: realisation, testing, installation, validation, commissioning, formal safety assessment

  4. Continual improvement, audit and review, reporting.

Week 11

Operations and Maintenance

  1. Planning and plans for operations

  2. Periodic testing procedures (on-line and off-line)

  3. Preventative maintenance, field instrumentation and logic solver diagnostics, system alarms)

  4. Integration with maintenance management system (PMs, work orders, failure history, backlog management)

  5. Managing system integrity, competency, change management

  6. System support (expertise, tools, test equipment, spares, repair and test cycle),

  7. Optimising maintenance (failure data, process shutdown capture, data analysis, hazard review, test interval and coverage)

  8. Decommissioning.

Week 12

Project and Revision

In the final weeks students will have an opportunity to review the contents covered so far. Opportunity will be provided for a review of student work and to clarify any outstanding issues. Instructors/facilitators may choose to cover a specialized topic if applicable to that cohort.

The Engineering Institute of Technology (EIT) is dedicated to ensuring our students receive a world-class education and gain skills they can immediately implement in the workplace upon graduation. Our staff members uphold our ethos of honesty and integrity, and we stand by our word because it is our bond. Our students are also expected to carry this attitude throughout their time at our institute, and into their careers.