Functional Safety 2016

Institute of Measurement and Control. Functional Safety 2016

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Figure 5 Digitalisation in the Process Industries

This latest transition goes by a number of different names, one of which is ”Industry 4.0" which

originates from a project in the high-tech strategy arm of the German government promoting the

computerization of manufacturing. It is one vision of what the next Industrial revolution will be.

The interpretation of exactly what form this “digitalisation” takes differs from one industry to another.

So for discrete manufacturing it may take the form of collaboration between cyber physical systems;

using the internet of things and the internet of services; involving digitalisation of the whole value

chain to achieve increased flexibility and productivity.

For the process industries it will likely involve digitalisation of plant across the whole plant life-cycle

and will incorporate topics such as integrated engineering and integrated operations.

Integrated Engineering

Integrated engineering is characterised by use of a shared, common data model and integrated

engineering toolsets across all disciplines with simulation capability built-in. This integration of

engineering capability will span the plant lifecycle right from initial design of process and plant through

to engineering, commissioning, operation and maintenance.

So what will this mean for functional safety? Studies indicate that over 50% of accidents stem from

failures in specification and design so tools that helps reduce these failures can potentially contribute

to safety. An integrated engineering approach to support all activities throughout the lifecycle can

help minimize systematic failures especially, but not only, those associated with specification and

design.

So for instance, as part of an integrated engineering approach, process equipment suppliers and

automation vendors would supply datasets which would combine with the process design, electrical

design, P & ID’s etc to form a common data model used by all across the lifecycle. Each dataset

would include all relevant engineering parameters and typically also include a 3D model of the piece

of equipment.

From a safety perspective this might mean, for instance, that the pressure rating on a vessel could be

linked in SIS specification to a corresponding trip limit in a SIS. It might not be used to directly set a

trip limit but it could certainly be used to cross check if a trip limit is sensible. If, at some later stage,

there is a proposal to change a trip limit during SIS specification, this linkage could be used to

highlight if the new trip limit is sensible and, if not, a specification error avoided.