FS 2: ISO 13849-1; IEC 62061 and Introduction to Low Demand Safety Systems

The training adopts a practical approach to the design of control systems that perform safety functions according to ISO 13849-1 (whose fourth revision was published in April 2023) and according to IEC 62061 (latest edition in 2021). The new edition has made the latter standard more usable and offers advantages over ISO 13849-1. The training also includes an introduction to safety systems in low-demand mode of operation (Low Demand).

The program is intended for machinery manufacturers equipped with relatively simple safety circuits, using interlocks, safety barriers (AOPD – Active Opto-electronic Protective Devices), contactors, and Variable Speed Drives (VSD), who are interested in expanding their knowledge on how to apply the IEC 62061 standard and who wish to understand the basics of high and low-demand safety systems.

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: 16 hours, in person or remotely.

PART 1: 4 hours

INTRODUCTION TO FUNCTIONAL SAFETY AND ISO 13849-1

• Machinery Safety and protective measures

• Interlocks

• Safety Logics

• Actuators: The contactor

• The basic principle of Functional Safety

• Introduction to High and Low Demand systems

• How to evaluate the minimum required reliability level

• ISO 13849-1: basic principles

• Category 1 – single channel

• Category 2

PART 2: 4 hours

ISO 13849-1 AND ARCHITECTURE EXAMPLES

• Categories 3 and 4 – dual channel

• The Simplified Procedure

• Main Safety Electrical Schematics

• Estimation of Diagnostic Coverage (DC)

• Main Pneumatic and Hydraulic Schematics

• Practical application examples

• Notes on Validation

PART 3: 4 hours

THE IEC 62061 STANDARD

• IEC 62061: Introduction

• Basic Subsystems Architecture A

• Basic Subsystems Architecture B

• Basic Subsystems Architecture C

• Basic Subsystems Architecture D

• Systems in Low Demand mode of operation

• Failure rates

• Hardware Fault Tolerance (HFT)

• How to calculate the SFF (Safe Failure Fraction)

• Type A and B Components

• The Proof Test

• Calculation of the PFD (Probability of Failure on Demand)

PART 4: 4 hours

ARCHITECTURE EXAMPLES AND VALIDATION

• Main Safety Wiring Diagrams

• Estimation of Diagnostic Coverage (DC)

• Main Pneumatic and Hydraulic Schematics

• Examples of Safety Subsystems

• Various examples of reliability calculation

• 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