Process Safety ServicesYokogawa Australia & New Zealand

Bulletin PS0317 - 01AU

2

Yokogawa - A Field Proven Safety Organisation Yokogawa process safety services, assist plant owners to meet their obligations to comply with the AS IEC 61511 Safety Lifecycle requirements, regardless of the lifecycle stage being examined. Whether it be from the preparation stage through to report finalisation, we work closely with our clients to ensure that all gaps are bridged and the activities are carried out as efficiently and smoothly as possible.

Yokogawa Functional Safety ExpertsYokogawa Functional Safety Experts are actively involved in mega-projects, from working in the client’s office carrying out SIS Front-End Engineering Design, SIS Realisation & Testing; to site SIS Validation, delivery and completion of commissioning. We ensure worldwide technical competency of our Functional Safety Experts, through a global Yokogawa Competency Profile Management System, which gives Yokogawa the agility to build the optimum safe solution regardless of the size or location of application.

Yokogawa’s user-focussed post and pre-sales support is a key reason our clients choose us, guaranteeing our clients industry leading life cycle support and long term sustainability.

Man

agem

ent o

f Fun

ctio

nal S

afet

y

Safe

ty L

ifecy

cle

- Str

uctu

re &

Pla

nnin

g

10 11

Other Means of Risk Reduction

Decommissioning

Modification

Hazard & Risk Allocation

Installation, Commissioning & Validation

Allocation of Safety Functions

Safety Requirements Specification

Design & Engineering of the SIS

Operation & Maintenance

1

2

3

4

5

6

7

8

Veri

ficat

ion

9

Process Safety Services 3

Conceptual Implementation Operational

3

Factory Certified Engineers To ensure we can continue to provide advanced innovative solutions to our customers, Yokogawa Australia maintains a national accreditation programme ensuring that our factory certified engineers meet stringent Yokogawa competency requirements.

The national accreditation programme ensures that Yokogawa certified engineers are trained and familiar with the very latest technology, industry knowledge and have access to exclusive factory tools that vastly increase service and engineering efficiencies. This allows new and existing installations to be commissioned in less time with higher reliability.

The programme encourages multi-skilling, providing opportunities for our engineers to build on their current skills and develop a well-rounded understanding of complex industrial applications.

Safety LifecycleEach of the phases outlined in the AS IEC 61511 Safety Lifecycle has a specific assessment process to ensure verified outcomes are met. Yokogawa have simplified the reading process by grouping the assessments which provides an understanding of where in your plant lifecycle a particular service would be required. The three phases are conceptual, implementation and operational.

“Since 2005 Yokogawa’s ProSafe-RS platform has grown to become the global number one in Process Safety.”

*Source: ARC Advisory Group, Process Safety Systems, Global Market Research Study

4

Implementation OperationalConceptual

Safety Integrity Level (SIL) SelectionOne of the challenges faced by process plants is being able to accurately budget for process safety equipment which protects people, plants and complies with government regulations.

Following the Hazards and Risk Assessment, the IEC 61511 safety lifecycle model requires that identified Safety Instrumented Functions (SIF’s) are assigned a target measure of their reliability to perform the safety function.

SIL Selection Workshop

Yokogawa Functional Safety Experts facilitate this process in allocating Safety Integrity Levels (SIL) to your plant SIFs. This facilitation is achieved through a SIL Selection Workshop, where all required and critical data is collated providing comprehensive information to accurately select the safety integrity levels.

Outcomes

Yokogawa provide a comprehensive and accurate result, to help you protect people, plant assets, and comply with legislation, while at the same time ensuring that expenditure on equipment is budgeted realistically. Using industry proven methods, which include Layers of Protection Analysis (LOPA), Risk Graphs and Risk Matrix in SIL Selection workshops, our clients are provided with:

• A comprehensive list of all uniquely identified SIFs• The SIL target for each SIF with respect to People

protection, Environmental protection and Asset protection

• Allocation of safety requirements to all layers of protection

Hazard & Risk Assessment (HAZOPS)The very first step in the process safety lifecycle is to ensure all potential hazards in the process and the associated equipment are identified. This step is crucial as all subsequent functional safety activities are designed around preventing these hazards or mitigating their impact.

Critical Assessment

Yokogawa works closely with the site plant engineers. All aspects of the process plant are scrutinized node-by-node, to identify hazards and operational issues. During this critical assessment, safeguards including Safety Instrumented Functions (SIFs) are identified and recorded for each of the situations.

Outcomes

Yokogawa utilises field experienced Functional Safety Experts, who are skilled in systematic hazard identification methods, to ensure all potential hazards in the process plant are identified. Upon completion of the Hazard and Risk Assessment clients are provided with:

• An overview of all possible hazard scenarios and operability issues with their initiating events and consequences

• A list of existing or new SIFs and other safeguards for each hazard scenario

• Documentation of the HAZOPs results and justification for Safety Functions

• A list of recommendations for improvements of the process or required clarification

Process Safety Services 5

Implementation OperationalConceptual

5

Safety Requirement SpecificationTo ensure safety specifications consider all aspects of process safety and that the SIS is designed and engineered to correct specifications prior to plant implementation. These specifications need to be maintainable and verifiable throughout the process safety lifecycle.

Documented Specifications

The Safety Requirement Specification generated by Yokogawa Functional Safety Experts, is a detailed document which describes functional and safety integrity requirements for the SIFs, specifying all aspects of the Safety Instrumented System (SIS).

It covers the SIS behaviour for all modes of plant operation, ensuring no stone is left unturned in the pursuit of process safety. These specifications need to be determined and documented referencing the HAZOPs, SIL Classification and SIL verification reports generated prior.

Accurate Safety Requirements

The end result is a comprehensive document that describes overall SIS requirements as well as details of each SIF’s safety and functional behaviour, ensuring that SIS Safety Requirements Specifications can be used to validate the SIS in later phases of the IEC 61511 process safety lifecycle.

SIL VerificationSIL selection ensures legislative safety requirements are met prior to final plant design. This helps to avoid costly redesign and rework of the process safety system by determining the intended SIS design meets all safety targets.

Design Review

Yokogawa Functional Safety Experts determine if the intended SIS design meets all safety targets as specified in the SIL Selection workshops. During the verification process, if SIFs are found not to meet their target SIL, Yokogawa experts will investigate options and advise the best course of action to take to reach a resolution for all issues discovered.

Peace of Mind

Carrying out this exercise early is insurance for plant designers to avoid costly re-design and associated rework, due to the inability to meet safety requirements in later stages of the project. Using Reliability Block Diagrams, Fault Tree Modelling and Yokogawa’s proprietary field tested SIL Verification (RSV) tool, we provide our clients with:

• A comprehensive report on Verified SIFs • Assurance that the SIS design meets required safety level

6

Implementation OperationalConceptual

Safety Assessment & Functional Safety Management AuditRegardless of the specific safety system in place, a Functional Safety Assessment (FSA) shall be carried out prior to plant start-up, as well as during operation.

Vendor Agnostic Auditing

SIS Validation activities are reviewed for completeness and any technical deficiencies present in the prior IEC 61511 process safety phases are identified. Readiness of the plant to move into the next phase of the safety lifecycle is thoroughly and professionally assessed.

Our Functional Safety Experts conduct SIS Functional Safety Management (FSM) audits in the industry to ensure our clients have a compliant FSM System in place. Different areas of FSM are scrutinized to ensure the plant has adequate procedures and systems in place to comply with FSM requirements. An FSM audit is included as part of the Functional Safety Assessment prior to plant start-up.

During the operational phase, we analyse if actual process safety indices and SIS performance are matching design assumptions. Identified weak links are addressed together with plant engineers to bridge any gaps, assuring safety is not compromised.

Independent Assessment & Review

Yokogawa Functional Safety Experts provide an independent assessment and review of the processes and preparation leading up to plant start-up. Gaps are identified and improvements are recommended and addressed towards a satisfactory resolution.

Functional Safety Assessments in the operations phase ensure SIS performance and plant safety are matching with expectations.

Design & EngineeringOnce the Safety Requirements Specification has been produced, the next step is the design of the ProSafe-RS Safety Instrumented System (SIS).

Global Competency

Yokogawa are actively involved in mega-projects, from working in the client’s office, carrying out Front-End Engineering Design, SIS Realisation & Testing; to site SIS Validation, delivery and completion of commissioning.

We ensure worldwide technical competency of our Functional Safety Experts, through a global Yokogawa Competency Profile Management System, which gives Yokogawa the agility to build the optimum safe solution regardless of the size or location of application.

Yokogawa’s user-focussed post and presales support is a key reason our clients choose us, guaranteeing our clients with industry leading life cycle support and long term.

Operational Excellence

Through partnering with a trusted and experienced safety solution design, engineering and safety systems manufacturer, safety outcomes are achieved with state of the art technology delivering operational excellence.

Process Safety Services 7

Implementation OperationalConceptual

Certified TrainingAny personnel involved in safety lifecycle activities are required to be competent for the roles they fill. Plant operators, technicians and engineers need to equip themselves with the necessary knowledge to perform their functions.

Certification Workshops

Yokogawa Australia provides a broad range of instructor led training courses to help customers enhance their knowledge and awareness of Yokogawa systems during different phases of project execution, as well as provide competency to control the process in a safe environment.

Yokogawa Technician, Operator and TÜV Rheinland FS Engineer courses are specifically designed to provide the necessary level of understanding of functional safety to plant operators, technicians and engineers to help them carry out their duties. At the end of the course they will have a sound understanding of safe practice in operation and maintenance as well as a clear understanding of how their actions affect process safety.

Our courses are designed to provide an understanding of the real-world challenges safety engineers and operators face in the industry and provides formal recognition of their achievement upon passing an assessment. Certification workshops can be held at an organisation’s premises or in an off-site training facility.

In order to achieve and maintain above industry standards our trainers are highly qualified in their subject area and possess formal tertiary and industry qualifications in addition to Training and Assessment standards.

Safety Function Monitoring

Yokogawa’s plant-wide safety monitoring solution provides analysis and reporting, helping you monitor the performance effectiveness of defined SIS (Safety Instrumented Systems) against their design targets.

Performance Monitoring, Analysis & Reporting

Exaquantum – Safety Function Monitoring will help you improve in the plant-wide monitoring, analysis and reporting of functional safety performance, of all the SIFs in your plant, as well as process behaviour.

Operational information from system and device activity is mapped against LOPA or HAZOP risk analysis analyses to report the effectiveness of actual safety performance against the design targets. Deviations from safety and design expectations are highlighted.

Regulatory Reports & Benchmarking

The benefits of our Safety Function Monitoring include, improved operational safety, visibility of safety performance at both control system and device level, optimisation of testing intervals, identification of spurious trips as well as a significant reduction in time/effort to produce regulatory reports and benchmark safety performance against design expectations to highlight possible safety issues.

Yokogawa Electric CorporationYOKOGAWA AUSTRALIA PTY LTDAustralia Head Office - SydneyTower A, 112-118 Talavera Road, Macquarie Park NSW 2213

Melbourne9 Lakeside Drive, Burwood East VIC 3151

PerthUnit 1, 115 Belmont Avenue, Belmont WA 6104

Adelaide96 Sir Donald Bradman Drive, Hilton SA 5033

Brisbane18A Metroplex Avenue, Murarrie QLD 4172

Contact UsEmail: prosafe@au.yokogawa.comWebsite: www.yokogawa.com/au

All Rights Reserved. Copyright©2017, Yokogawa Electric CorporationBulletin PS0317 - 01AU

YOKOGAWA NEW ZEALAND LTDNew Zealand Head Office - AucklandUnit 1H, 5 Ceres Court, Albany Auckland 0632

Christchurch11B Sheffield Crescent, Burnside Christchurch 8053