INTRODUCTION

The complexity of modern process technological systems, coupled with tight process limit makes failure analysis a difficult task. There is an increased awareness that risk management impacts every aspect of process operation. Modern International Standards highlights the crucial role of risk assessment for the design and reliability of process machinery and protective systems

WHO SHOULD ATTEND?

·         Safety Engineers

·         Maintenance Engineers

·         Control/Instrumentation Specialists

·         Mechanical Engineers

·         Electrical Engineers

·         Process Specialists

PROGRAMME OBJECTIVES

The overall objective is to ensure that delegates are familiar with the concept of reliability, root-cause and failure analysis. The programme has been designed to enable delegates upon completion to be able to:

·         Apply the concept of reliability technology for failure analysis and to calculate reliability of systems

·         Design and calculate the reliability of control and protective systems

·         Assess the adequacy of High Integrity Protective Systems ‘HIPS’

·         Select the appropriate Safety Integrity Levels ‘SIL’s for protective and safety systems in accordance with IEC 61508

·         Ensure consistent optimization of resource allocation for production, maintenance and safety, based on risk and cost-benefit analysis

·         Familiar with risk assessment techniques to new projects and existing machinery/systems

·         Apply Fault Tree Analysis as a risk assessment, fault diagnosis and root-cause analysis tool

·         Recognize relevant International Standards for risk assessment and safety of machinery

TRAINING METHODOLOGY

The programme shall be presented by a combination of interactive lectures, videos, and knowledge and understanding further established by way of a number of syndicate group exercises. Delegates are always encouraged to interact with the Presenter and with each other.

PROGRAMME SUMMARY

This programme is intended to updated participants with the most relevant up-to-date EU and International Standards in the field of Safety Technology. It aims to sharpen delegates skills in analyzing hardware failures and identifying their root-causes. It also improves experience in the application of reliability technology for the selection of appropriate Safety Integrity Levels ‘SIL’s for protective and safety systems in accordance with IEC 61508.

·         Organisational Impact

·         Professional development of staff; the organisation should be able to prevent accidents and minimise losses through improved reliability and safety

·         Awareness of tried and tested International practical principles to make quantifiable decisions to assist in evaluating risks from engineering options.

·         Enable the delegate to apply the principles of safety engineering and risk assessment back at his or her workplace by putting into practice the practical knowledge gained from the programme

·         Ensure that modern International Safety Standards are implemented in new projects

·         Personal Impact             

·         Promotes a proactive attitude within the individual to failure and hazazrd analysis

·         Introduce the proactive concept and benefits of safety engineering and hazard / risk assessment analysis

·         Help to recognise the range of the key factors to be considered in the process of minimizing failures and equipment down-time

·         Introduce the delegate to the methods and techniques for evaluation hazards across a variety of industry sectors

·         Enlighten the delegate to the importance of continued learning from incidents and root-causes for failures

PROGRAMME OUTLINE

DAY 1 - ANALYSIS OF FAILURES ·         Introduction into Reliability Technology ·         Reliability calculation ·         Types of failures: the bathtub curve ·         Types of inspection and maintenance systems ·         Weibul Distribution and reliability parameters- BS 5760 ·         Types of systems: series/parallel and non series/non parallel ·         Bayes theorem and systems reliability calculations

DAY 2 - PROTECTIVE SYSTEMS DESIGN AND RELIABILITY ·         Elements of control and protective systems ·         Reliability of control systems ·         The concept of fractional dead time and protective systems ·         High Integrity Protective Systems ‘HIPS’ ·         Hazardous Area Classification: the EU ATEX Directive ·         Active fire/explosion protection systems ·         EN 954-1: Control Systems with safety-related functions ·         IEC 61508: E, E and PES in safety-related applications.

DAY 3 - ROOT CAUSE ANALYSIS TECHNIQUES ·         Asset Integrity Assurance ·         Failure Modes and Effects Analysis FMEA ·         Commercial software for FMEA ·         Fault Tree Analysis ‘FTA’ ·         Quantification of Fault Trees ·         Fault trees and fault diagnisis

DAY 4 - MACHINERY SAFETY ·         Causes and methods of preventing machinery accidents ·         The EU and International Machinery Safety Standards ·         Types of Machinery Safeguards and Safety Devices ·         Machinery/work equipment hazards identification ·         EN 1050: Machinery and work equipment risk assessment

DAY 5 - ROLE OF RISK ASSESSMENT ·         Hazards identification techniques ·         Risk evaluation ·         Elements of accident causation ·         Types of root causes – technical and organizational ·         International machinery safety standard ISO 14121 ·         Programme review