{"id":1816,"date":"2023-02-22T11:39:38","date_gmt":"2023-02-22T10:39:38","guid":{"rendered":"https:\/\/www.gt-engineering.it\/approfondimenti\/%tipologia_approfondimento%\/high-vs-low-demand-eng\/"},"modified":"2025-12-07T14:59:55","modified_gmt":"2025-12-07T13:59:55","slug":"high-vs-low-demand-eng","status":"publish","type":"approfondimento","link":"https:\/\/www.gt-engineering.it\/en\/insights\/process-safety-processi-gt-engineering\/high-vs-low-demand-eng\/","title":{"rendered":"High versus Low Demand"},"content":{"rendered":"\n\n    \n        <section\n            data-name=\"Contenuto testuale con immagine\"\n            class=\"bow-gte-testo-media u-spacer-base\"\n            id=\"\"\n        >\n            \n<div class=\"o-text-media px-side-spacer sm:px-side-spacer-sm lg:px-side-spacer-tablet 2xl:px-side-spacer-desktop flex flex-wrap items-start md:block\">\n\n    \n        \n                    <div\n                class=\"h-auto mb-6 md:mb-4 lg:mb-8 xl:mb-9 float-left mr-6 md:mr-4 lg:mr-8 xl:mr-9  overflow-hidden shadow-content-image w-full md:w-1\/3\"\n            >\n                \r\n\r\n    \r\n        \r\n            \r\n                \r\n                    <picture\r\n                        class=\"\"\r\n                                            >\r\n                                                                                                        <source\r\n                                media=\"(max-width: 150px)\"\r\n                                width=\"150\"\r\n                                height=\"150\"\r\n                                srcset=\"https:\/\/www.gt-engineering.it\/wp-content\/uploads\/2023\/02\/IMG_6462-1-150x150.jpg.webp\"\r\n                                type=\"image\/webp\"\r\n                            \/>\r\n                                                                                <source\r\n                                media=\"(max-width: 300px)\"\r\n                                width=\"300\"\r\n                                height=\"200\"\r\n                                srcset=\"https:\/\/www.gt-engineering.it\/wp-content\/uploads\/2023\/02\/IMG_6462-1-300x200.jpg.webp\"\r\n                                type=\"image\/webp\"\r\n                            \/>\r\n                                                                                <source\r\n                                media=\"(max-width: 768px)\"\r\n                                width=\"768\"\r\n                                height=\"512\"\r\n                                srcset=\"https:\/\/www.gt-engineering.it\/wp-content\/uploads\/2023\/02\/IMG_6462-1-768x512.jpg.webp\"\r\n                                type=\"image\/webp\"\r\n                            \/>\r\n                                                                                <source\r\n                                media=\"(max-width: 1000px)\"\r\n                                width=\"1000\"\r\n                                height=\"667\"\r\n                                srcset=\"https:\/\/www.gt-engineering.it\/wp-content\/uploads\/2023\/02\/IMG_6462-1.jpg.webp\"\r\n                                type=\"image\/webp\"\r\n                            \/>\r\n                                                                            <img\r\n                            class=\"a-image transparent border-image h-auto  w-full\"\r\n                                                        srcset=\"https:\/\/www.gt-engineering.it\/wp-content\/uploads\/2023\/02\/IMG_6462-1.jpg.webp\"\r\n                                                        title=\"IMG_6462\"\r\n                                                        type=\"image\/webp\"\r\n                        \/>\r\n                    <\/picture>\r\n\r\n                \r\n\r\n                    \r\n    \r\n            <\/div>\n        \n                    <div class=\"relative w-full\">\n                \n<div class=\"a-text font-text text-base normal mt-8 first:mt-0 space-y-4\">\n    <p><strong>THE DOUBT\u00a0:<\/strong> What does it mean for a Safety Control System to operate in <strong><em data-start=\"236\" data-end=\"249\">High Demand<\/em> or <em data-start=\"253\" data-end=\"265\">Low Demand<\/em><\/strong>, and why is it important to know the difference?<\/p>\n<p>&nbsp;<\/p>\n<p style=\"text-align: justify;\"><strong>CONSIDERATIONS:\u00a0<\/strong>An analogy with urban mobility can help clarify this concept. Imagine two cars:<\/p>\n<ul>\n<li data-start=\"424\" data-end=\"453\">one that is used every day,<\/li>\n<li data-start=\"456\" data-end=\"510\">and another that is used only once every four years.<\/li>\n<\/ul>\n<p data-start=\"512\" data-end=\"894\">In both cases, we expect the car to be reliable. However, if we do not specify that the second car will remain parked for four years, we may be disappointed when it fails to start\u2014perhaps because the battery has discharged over time. The same principle applies to safety control systems: the techniques to reach a high reliability level depends on how frequently the system is expected to operate.\u00a0Because of this, safety systems are classified into two main categories:<\/p>\n<ul>\n<li data-start=\"972\" data-end=\"1005\">Safety Systems<strong data-start=\"972\" data-end=\"1005\"> in High Demand<\/strong><\/li>\n<li data-start=\"1008\" data-end=\"1040\">Safety Systems<strong data-start=\"1008\" data-end=\"1040\"> in Low Demand<\/strong><\/li>\n<\/ul>\n<p data-start=\"1083\" data-end=\"1534\">\n<p data-start=\"1083\" data-end=\"1534\">In <strong data-start=\"1086\" data-end=\"1104\">Process Safety<\/strong>, most Safety Instrumented Systems (SIS) operate in the <strong data-start=\"1160\" data-end=\"1174\">Low Demand<\/strong> mode.<br data-start=\"1180\" data-end=\"1183\" \/>Consider a high-pressure switch on a tank that is designed to close an incoming gas line. The process control system (BPCS) keeps the pressure within limits, and operators receive alarms well before the high-pressure trip point is reached. If the BPCS works correctly, the safety switch may never activate \u2014 or might operate only once every &#8230; four years?<\/p>\n<p data-start=\"1536\" data-end=\"1669\">This raises a critical question: <strong data-start=\"1571\" data-end=\"1669\">How can we be confident that a device will still function correctly after years of inactivity?<\/strong><\/p>\n<p data-start=\"1671\" data-end=\"1900\">Because Low Demand systems rarely operate, failures can accumulate unnoticed over long periods. This requires specific design criteria, testing intervals, and reliability calculations.<\/p>\n<p>&nbsp;<\/p>\n<p data-start=\"1944\" data-end=\"2199\">In <strong data-start=\"1947\" data-end=\"1967\">Machinery Safety<\/strong>, we often deal with <strong data-start=\"1988\" data-end=\"2003\">High Demand<\/strong> Safety Control Systems (SCS). For example, a safety interlock on a protective gate may be opened every day. Each operation provides immediate confirmation that the device is still functional.\u00a0If two interlocks are installed on the same gate, we can reasonably assume that <strong data-start=\"2281\" data-end=\"2333\">only one failure might occur between activations<\/strong>\u2014say, between today and tomorrow\u2014because the time window for failure accumulation is very small. Therefore, the situation is very different from the high-pressure switch that may remain &#8220;idle&#8221;\u00a0 for years and yers. The more frequently a safety function is demanded, the more directly and frequently its reliability is &#8220;automatically&#8221; verified.<\/p>\n<p style=\"text-align: justify; margin: 0cm 0cm 8pt;\"><span style=\"margin: 0cm 0cm 8pt; text-align: justify;\">That is, in essence, the reason why the \u201ctwo worlds\u201d of high and low demand run in parallel and have quite different approaches. <\/span><\/p>\n<p>&nbsp;<\/p>\n<p><span style=\"margin: 0cm 0cm 8pt; text-align: justify;\">The reference standard for Low Demand Applications is <strong>IEC 61511<\/strong>:<\/span><\/p>\n<blockquote>\n<p style=\"margin-bottom: 6.0pt; margin: 0cm 0cm 8pt;\">IEC 61511-1: 2016. <em>Functional safety &#8211; Safety instrumented systems for the process industry sector &#8211; Part 1: Framework, definitions, system, hardware and application programming requirements<\/em><\/p>\n<p style=\"margin-bottom: 6.0pt; margin: 0cm 0cm 8pt;\">IEC 61511-2: 2016. <em>Functional safety &#8211; Safety instrumented systems for the process industry sector &#8211; Part 2: Guidelines for the application of IEC 61511-1:2016<\/em><\/p>\n<p style=\"margin-bottom: 6.0pt; margin: 0cm 0cm 8pt;\">IEC 61511-3: 2016. <em>Functional safety &#8211; Safety instrumented systems for the process industry sector &#8211; Part 3: Guidance for the determination of the required safety integrity levels<\/em><\/p>\n<\/blockquote>\n<p style=\"text-align: justify; margin: 0cm 0cm 8pt;\"><span style=\"margin: 0cm 0cm 8pt; text-align: justify;\">While, for high demand, there are 2 different standards: <strong>IEC 62061 and ISO 13849-1<\/strong>:<\/span><\/p>\n<blockquote>\n<p style=\"margin-bottom: 6.0pt; margin: 0cm 0cm 8pt;\">IEC 62061: 2021. <em>Safety of machinery &#8211; Functional safety of safety-related electrical, electronic and programmable electronic control systems<\/em><\/p>\n<p>ISO 13849-1: 2023 &#8211; <em>Safety of machinery \u2014 Safety-related parts of control systems \u2014 Part 1: General principles for design<\/em><\/p>\n<p>ISO 13849-2:2012 &#8211; <em>Safety of machinery \u2014 Safety-related parts of control systems \u2014 Part 2: Validation<\/em><\/p><\/blockquote>\n<p>&nbsp;<\/p>\n<p style=\"text-align: justify; margin: 0cm 0cm 8pt;\">In 2023, we published <a href=\"https:\/\/www.gt-engineering.it\/en\/pubblications\/functional-safety-of-machinery\/\">a book<\/a> on the High demand Safety Standards. Inside, we also describe how to tackle <strong>mixed systems.<\/strong><\/p>\n<p>&nbsp;<\/p>\n<p><span style=\"margin: 0cm 0cm 8pt; text-align: justify;\"><strong>ISO 13849-1<\/strong> only deals, with High Demand Safety Related Parts of the control system (SRP\/CS), while it is the role of IEC 62061 <strong>to tackle systems containing both high and low demand loops.<\/strong><\/span><\/p>\n<p data-start=\"149\" data-end=\"550\">Within the technical committee responsible for IEC 62061\u2014where GT Engineering contributes at the international level\u2014there is growing interest in addressing <strong data-start=\"306\" data-end=\"320\">Low Demand<\/strong> applications. The intent is not to overlap or \u201ccompete\u201d with IEC 61511, but to acknowledge that in the Machinery sector manufacturers may encounter machines that incorporate <strong data-start=\"495\" data-end=\"547\">both High Demand and Low Demand safety functions<\/strong>.<\/p>\n<p data-start=\"552\" data-end=\"919\">However, despite this shared interest, the working group has not yet reached a consensus on how Low Demand should be treated within the context of machinery safety. The methodologies used today in IEC 62061 and ISO 13849-1 are built around architectures and metrics suited for High Demand or Continuous mode, and they do not seamlessly extend to Low Demand scenarios.<\/p>\n<p data-start=\"552\" data-end=\"919\">\n<p data-start=\"921\" data-end=\"1304\">Consider, for example, a <strong data-start=\"946\" data-end=\"972\">heat treatment furnace<\/strong> equipped with high-temperature thermocouples designed to protect the chamber if its temperature exceeds the allowable limit. This protection function clearly operates in <strong data-start=\"1143\" data-end=\"1157\">Low Demand<\/strong> mode: under normal operation, this High temperature safety function will never trigger, and the demand frequency may be extremely low\u2014possibly only once in several years.<\/p>\n<p data-start=\"1306\" data-end=\"1446\">In such cases, it is not sufficient to simply apply the existing rules of ISO 13849-1 or IEC 62061. A Low Demand safety function requires:<\/p>\n<ul>\n<li data-start=\"1450\" data-end=\"1517\">different reliability metrics (typically PFDavg rather than PFH),<\/li>\n<li data-start=\"1520\" data-end=\"1585\">different assumptions about fault accumulation and diagnostics,<\/li>\n<li data-start=\"1588\" data-end=\"1752\">and often <strong data-start=\"1598\" data-end=\"1647\">methodologies derived from the process sector<\/strong>, or at least <strong data-start=\"1661\" data-end=\"1702\">additional engineering considerations<\/strong> that go beyond the standard machinery frameworks.<\/li>\n<\/ul>\n<p data-start=\"1754\" data-end=\"2054\">This is precisely why the working group continues to explore how Low Demand concepts might be incorporated into future revisions of IEC 62061, ensuring that manufacturers have appropriate tools to design and validate safety functions that operate only rarely but must function flawlessly when needed.<\/p>\n<p>In this respect, a new <a href=\"https:\/\/www.gt-engineering.it\/en\/technical-standards\/en-iec-standards\/iec-ts-63394-gt-engineering-ita\/\">Technical Standard<\/a> was published in 2023:<\/p>\n<blockquote><p><strong>IEC TS 63394: 2023<\/strong> \u2013 <em>Safety of machinery \u2013 Guidelines on functional safety of safety-related control syste<\/em>m<\/p><\/blockquote>\n<p>In the <strong>Annex J,<\/strong> it is shown a way to tackle safety systems with both High and Low demand mode (Mixed Systems). <strong>The same aproach will also be included in the new edition of IEC 61508-6, that will see the light in 2026.<\/strong><\/p>\n<p>&nbsp;<\/p>\n<p style=\"text-align: justify; margin: 0cm 0cm 8pt;\"><strong>CONCLUSIONS:<\/strong><\/p>\n<p style=\"text-align: justify; margin: 0cm 0cm 8pt;\"><span style=\"margin: 0cm 0cm 8pt; text-align: justify;\">The distinction between <strong>High and Low Demand Safety Applications is important<\/strong>, especially for Machineries. When analysing each safety loop, always think about how often it will most likely be used or triggered. <\/span><\/p>\n<p style=\"text-align: justify; margin: 0cm 0cm 8pt;\"><span style=\"margin: 0cm 0cm 8pt; text-align: justify;\"><strong>If it is at least once a week,<\/strong> you can reason in terms of High Demand and you do not need to make other considerations. <\/span><\/p>\n<p style=\"text-align: justify; margin: 0cm 0cm 8pt;\"><span style=\"margin: 0cm 0cm 8pt; text-align: justify;\">For frequencies less than that, <strong>you need to think about additional maintenance and verifications<\/strong>. <\/span><\/p>\n<p style=\"text-align: justify; margin: 0cm 0cm 8pt;\"><span style=\"margin: 0cm 0cm 8pt; text-align: justify;\">For frequencies less than once per year (<strong>low demand<\/strong>), you need <strong>to use the approach of IEC 61511-1.<\/strong><\/span><\/p>\n<\/div>            <\/div>\n        \n        \n                <div class=\"clear-both\"><\/div>\n        \n\n    <\/div>\n        <\/section>\n\n    \n","protected":false},"excerpt":{"rendered":"<p>THE DOUBT&nbsp;:&nbsp;What does it mean that a Safety Control Systems is operating in High or in Low Demand and why is it important to know it?<\/p>\n<p>CONSIDERATIONS:&#8230;<\/p>\n","protected":false},"author":1,"featured_media":1817,"parent":0,"menu_order":19,"template":"","meta":{"_acf_changed":false,"footnotes":""},"tipologia_approfondimento":[49],"class_list":["post-1816","approfondimento","type-approfondimento","status-publish","has-post-thumbnail","hentry","tipologia_approfondimento-process-safety-processi-gt-engineering"],"acf":{"sottotitolo":"","allegati":null},"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.2 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>High versus Low Demand<\/title>\n<meta name=\"description\" content=\"THE DOUBT\u00a0:\u00a0What does it mean that a Safety Control Systems is operating in High or in Low Demand and why is 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