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Naresh Bajaj, P.Eng., CFSP Electrical and Control Engineer, Autopro Automation Consultants Ltd. Stephane Boily, P.Eng., CFSE Safety System Technology Manager Autopro Automation Consultants Ltd. 2012 Safety Control Systems Conference
Agenda
Introduction Diagnostic Tests Vs. Proof Tests Influence of Proof test coverage (CPT) on PFDavg and SIL integrity Methods to quantify CPT Proof test procedure development process Guidelines in building effective proof test procedure
Introduction
Periodic proof test and diagnostic test are integral elements of the overall Safety Instrumented System(SIS) design Primary objective is to reveal undetected failures It ensures that the system will provide the risk reduction required to safely operate the facility.
is the proof test coverage; is the dangerous undetected failure rate identified by the proof test; and is the total dangerous undetected failure rate.
1 = + 2 2
: Proof test interval : Mission Time
Where:
Determining CPT
Certified Equipment
Proof test procedure and CPT provided by manufacturer.
Credit System
Estimating CPT for existing facilities with no data available.
Certified Equipment
Certified Equipment
Total 60%
Total 65%
1) full stroke test Proof Test Coverage = 250/(250+200+100+25) = 43% 2) Time stroking test Proof Test Coverage = 200/(250+200+100+25) = 35% 3) Leak test Proof Test Coverage = 100/(250+200+100+25) = 17%
Poor Practices
Developing proof test procedures in a cocoon without the participation of the maintenance technicians who will be responsible for executing them. Calibrating the sensors prior to performing the trip test. Cleaning or performing preventive maintenance prior to performing the trip test. Claiming 100% proof test coverage.
Conclusion
The proof testing of SIS is defined in the safety standards (IEC 61508 and 61511) but the interpretation of it is ambiguous. It was confirmed that the impact of the CPT is real. Theres no such thing as a perfect proof test although it is desirable to strive to get as close to it as possible. Choosing accurate CPT has its own limitations due to different practical considerations and various factors influence the outcome.
References
[1] Feng Tao, Users need detailed reliability analysis not just numbers, IDC Safety Control Systems Conference 2010 [2] W.M. Goble and H.Cheddie, Safety Instrumented Systems Verification, Practical Probabilistic Calculations [3] OBrien, C. and Bredemeyer, L., Final Elements & the IEC 61508 and IEC 61511 Functional Safety Standards, [4] Safety Equipment Reliability Handbook, exida [5] D. Fournier, How critical is Proof Test Coverage?, You asked: Functional Safety Clarified, Canadian Process Equipment & Control News Aug 2009 [6] Principles for proof testing of safety instrumented systems in the chemical industry, Health & Safety Executive, contract research report 428/2002. [7] Gyrgy Baradits, Jnos Madr, Jnos Abonyi, Novel Model of Proof Test Coverage Factor, 10th International Symposium of Hungarian Researchers on Computational Intelligence and Informatics, Nov 2009