Last edit: 11/11/2023
Training objective
The program is for Mechanical and Electrical Engineers woking for a Machinery Manufacutrer who would like to get an in depht and at the same time practical training on how to design and verify Safety Control Systems for Machinery. The program is provided in English, in four remote Sections of 4 hours each (ZOOM Platform).
The Training is based upon the Second Edition of IEC 62061 (March 2021) and the 2023 Edition (the fourth) of ISO 13849-1.
DIFFERENCES BETWEEN THE FS1, FS2 and FS3 COURSES:
- If the goal is a good knowledge of ISO 13849-1, we recommend the 8-hour FS1 course.
- If you are also interested in IEC 62061 and want to improve your knowledge on the differences between High and Low Demand systems, we recommend FS 2.
- However, if some participants already have a good knowledge of ISO 13849-1 and are interested in learning more not only about IEC 62061, but also about the Low Demand technical standards (like IEC 61511), understand how to read a certificate of a “SIL certified” pressure transmitter, how to handle “mixed” systems, i.e. with loops in both high and low demand and in general to obtain an excellent knowledge of the standards related to functional safety, we recommend the FS 3.
Moreover, the FS 2 program contains all the FS 1 subjects and FS 3 contains all the programs of both FS1 and FS 2.
Content
SECTION 1: 8 hours
THE BASICS OF RELIABILITY ENGINEERING
- The birth of Reliability Engineering
- Basic definitions and concepts of Reliability
- Faults and Failures
- Random and Systematic Failures
- Probability elements beyond Reliability concepts
- Failure Rate λ
- Mean Time Between Failures (MTBF)
- Reliability Functions in low and high demand
- Weibull Distribution
- Markov Graphs
- Logical and physical representation of a Safety Function
WHAT IS FUNCTIONAL SAFETY
- brief history of functonal safety standards
- 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 Constraint
- Mean Time to Failure (MTTF)
- Common Cause Failure (CCF)
- Proof Test
- Mission Time and Useful Lifetime
SECTION 2: 8 hours
INTRODUCTION TO ISO 13849-1 and IEC 62061
- Risk Assessment and Risk Reduction
- Protective and Preventive measures
- Functional Safety as part of the Risk Reduction measures
- SRP/CS, SCS and the Safety Functions.
- Examples of Safety Functions: Safety-related stop, Safety Sub-functions related to Power Drive Systems (PDS), Manual Reset, Restart function, the Emergency Stop Function
- Reliability of a Safety Function in Low Demand.
- The Reliability of a 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 Approaches
- Safety Requirements Specification.
- Decomposition of the Safety Function.
- Iterative Process to reach the required Reliability Level.
- Systematic Failures and the Basic Requirements of a Safety Function.
- Fault Considerations and Fault exclusion.
- Technical Standards for Control Circuit devices: Direct Opening Action, Contactors used in Safety Applications, how to avoid systematic faults with contactors, an example how to protect contactors, implications coming from IEC 60204-1, Enabling and Hold to run Devices
- Measures for the avoidance of systematic failures: Basic Safety Principles and Well-tried Safety Principles,
- Fault Masking.
DESIGN AND EVALUATION OF A SAFETY FUNCTION
- Subsystems, Subsystem Elements and Channels
- Evaluation of an SRP/CS
- Well-tried Components
- Proven in use devices
- Prior use devices
- Evaluation of an SCS
- Information for Use
- Safety Software Development
- Limited and Full Variability Language
- The V-Model
- Software classifications according to IEC 62061
- Low demand applications in Machinery
SECTION 3: 8 hours
CATEGORIES OF ISO 13849-1
- Physical and Logical representation of the Architectures
- The Categories of ISO 13849-1: Category B, Category 1, Category 2, Category 3, Category 4, Basic Requirements for the Categories
- Simplified Procedure for estimating the Performance Level
- Conditions for the simplified procedure
- How to calculate MTTFD of a SUBSYSTEM
- Estimation of the Performance Level
- The Alternative Approach
ARCHITECTURES OF IEC 62061
- 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 for the Architectures
- Relationship between λD and MTTFD
SECTION 4: 4 hours
EXAMPLE OF ELECTRICAL ARCHITECTURES
EXAMPLES OF PNEUMATIC AND HYDRAULIC ARCHITECTURES
VALIDATION
- The Validation Plan
- Fault List
- Validation of measures against systematic failures
- Information needed for the Validation
- Analysis and Testing
Instructor
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