FS 3: Advanced Course - Reliability of Safety Systems in High and Low Demand, ISO 13849-1, IEC 62061, IEC 61508, IEC 61511

The program is designed for designers of any type of safety system, whether in the world of machinery (interlocks, safety barriers), AOPD – Active Opto-electronic Protective Devices), contactors, and Variable Speed Drives (VSD) or in the process industry (pressure and temperature transmitters, sensors used in a Low Demand environment). The standards covered in the course are ISO 13849-1 and IEC 62061 for High Demand applications, and IEC 61508 and IEC 61511 for Low Demand applications.

TARGET AUDIENCE: Electrical and mechanical technicians who work for a Machinery manufacturer.

DIFFERENCES BETWEEN FS 1, FS 2, AND FS 3 COURSES:

• The FS 1 course is for those who want to gain a good knowledge of ISO 13849-1, which allows them to calculate the Performance Levels of a safety function.

• The FS 2 course is for those who are also interested in IEC 62061 (calculation of Safety Integrated Level – SIL) and want to explore the differences between systems in High and Low Demand.

• Finally, the FS 3 course is suitable for those who already have a good knowledge of ISO 13849-1 and are interested in exploring the following aspects: IEC 62061, the standards on Low Demand (IEC 61508 and IEC 61511), how to interpret a certificate for a “SIL-certified” pressure transmitter, how to manage “mixed” systems (i.e., with loops in both High and Low demand), and generally gain excellent knowledge of the standards related to Functional Safety.

The FS 1, FS 2, and FS 3 programs are cascaded: FS 2 includes the entire FS 1 course program, while the FS 3 course includes the entire programs of both FS 1 and FS 2.

DURATION: 28 hours, in person or remotely.

THE FUNDAMENTALS OF RELIABILITY ENGINEERING

• The birth of Reliability Engineering

• Definitions and basic concepts of reliability

• Faults and Failures

• Random and Systematic Faults

• Elements of probability beyond the concepts of Reliability

• Failure Rate λ

• Mean Time Between Failures (MTBF)

• Reliability functions in Low and High Demand

• The Weibull distribution

• Markov graphs

• Logical and physical representation of a Safety Function

WHAT IS FUNCTIONAL SAFETY

• Historical notes on Functional Safety

• Safety Systems in High and Low Demand

• What is a Safety Control System

MAIN PARAMETERS

• Failure Rate λ

• Safe Failure Fraction (SFF)

• Diagnostic Coverage (DC)

• Safety Integrity and Architectural Constraints

• Mean Time to Failure (MTTF)

• Common Cause Failure (CCF)

• Proof Test

• Mission Time and Useful Lifetime

INTRODUCTION TO ISO 13849-1 AND IEC 62061 STANDARDS

• Risk Assessment and Reduction

• Preventive and Protective Measures

• Functional Safety as a measure for risk reduction

• SRP/CS, SCS, and Safety Functions

• Examples of Safety Functions: safe stop, sub-functions of safety related to power drive systems (PDS), manual reset, restart function, emergency stop function

• Reliability of the Safety Function in Low Demand

• Reliability of the Safety Function in High Demand

• Determination of the required PL (PLr) according to ISO 13849-1

• Determination of the required SIL (SILr) according to IEC 62061

• Differences between the two approaches

• The Safety Requirement Specifications (SRS)

• Decomposition of the Safety Function

• The Iterative Process to achieve the Required Reliability Level

• Systematic Failures and the basic requirements of a Safety Function

• Fault considerations and Fault Exclusion (EN ISO 13849-1)

• Technical Standards for Control Circuit devices: Direct opening action, contactors used in Safety applications, how to avoid systematic faults with contactors, an example of contactor protection, implications arising from IEC 60204-1, Enabling and Maintaining devices.

• Measures to avoid Systematic Failures: Basic Safety Principles and Well-Tried Safety Principles (EN ISO 13849-1)

• Fault Masking

DESIGN AND EVALUATION OF A SAFETY FUNCTION

• Subsystems, Elements of a Subsystem, and Channels

• Evaluation of an SRP/CS

• Well-Tried Components

• “Proven in Use” Devices

• “Prior Use” Devices

• Evaluation of an SCS

• Information for use

• How to develop safety software

• Limited and Full Variability Language

• The V-Model

• Classification of software according to IEC 62061

• Low Demand applications in machinery

THE ISO 13849-1 CATEGORIES

• Physical and logical representation of the Categories

• The ISO 13849-1 Categories: Category B, Category 1, Category 2, Category 3, Category 4, the basic requirements of the Categories

• Simplified procedure for Performance Level estimation

• The conditions for simplified procedures

• How to calculate the MTTFD of a Subsystem

• Estimation of the Performance Level

• The Alternative Approach

THE IEC 62061 ARCHITECTURES

• The four Architectures

• The Simplified Approach

• How to calculate the PFHD of a subsystem

• Basic Subsystem Architecture A: 1oo1

• Basic Subsystem Architecture B: 1oo2

• Basic Subsystem Architecture C: 1oo1D

• Basic Subsystem Architecture D: 1oo2D

• Basic requirements of the Architectures

• The correlation between λD and MTTFD

EXAMPLES OF ELECTRICAL ARCHITECTURES

EXAMPLES OF PNEUMATIC AND HYDRAULIC ARCHITECTURES

VALIDATION

• The Validation Plan

• Fault List

• Validation of measures against Systematic Failures

• Information required for Validation

• Analysis and Tests

GT Engineering is member of the following IEC and ISO Technical Committees:

• Member of the Technical Committee TC 44/MT 62061 for IEC 62061: Safe control systems for machinery
• Member of the Technical Committee TC 44/PT 63394 for IEC TS 63394: Guidelines on safe control systems for machinery
• Member of the Technical Committee TC 65/SC 65A/MT 61511 for IEC 61511: Functional safety – Safety instrumented systems for the process industry
• Member of the Technical Committee TC 65/SC 65A/MT 61508-1-2 for IEC 61508: Maintenance of IEC 61508-1, -2, -4, -5,-6 and 7
• Member of the Technical Committee ISO/TC 199, for ISO 13849-1