Process Safety Management
and
Functional Safety Management
…. Spot the difference
A few key points for those Directors and Managers
responsible for overseeing safety trips
by The
61508 Association
SAFETY INSTRUMENTED SYSTEMS
are too important to leave to chance!
DISCLAIMER: Whilst every effort has been made to ensure the accuracy of the information contained in this
document neither The 61508 Association nor its members will assume any liability for any use made thereof.
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Important and
surprising fact …
Every process plant, including yours, has
safety trips
Some of those safety trips are high reliability
or high integrity, therefore IEC61508 or one
of the related group of standards, such as
IEC61511, applies.
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BS EN 61508: Hazard & Risk Analysis
The Safety Instrumented System
Fills the gap – IF the other protections are present
TOLERABLE
RISK LEVEL
UNACCEPTABLE
RISK LEVEL
IDENTIFIED RISK
Required Risk Reduction
By SIL
System
By Other Technology
(Relief system / Vessel
design etc.)
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By External Factors
(Location /Bunding etc)
Important and
surprising fact …
Since SIL rated trips fill the gap and make the risk
TOLERABLE to the company, ....
the SIL and its PFDavg are only true IF all of the other
layers of protection are present and working.
This means that Functional Safety Management is
about maintaining ALL of the layers of safety
protection so that each SIL and its PFDavg remain
true.
FSM is about maintaining all of the safety. FSM is
NOT strangely restricted to the SIL rated system.
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The 61508 Association does not believe in
doing the same work twice … just because
it appears in more than one standard.
Process safety management is good practice
for any company … but it is not mandatory
… by contrast Functional safety management
is mandatory under IEC61508 Part 1
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Approved Code of
Practice
In countries around the world IEC61508 and IEC61511 are
mandated. Take, for example, the UK:
D.S.E.A.R. is the ..... Dangerous Substances and Explosive Atmospheres Regulations
DSEAR in the UK is mainly ATEX, but it is not just ATEX, and DSEAR applies to everyone
ATEX in EUROPE is “EAR”, the Explosive Atmospheres Regulations .... but we have the
“Dangerous Substances and...”
So DSEAR is more than just ATEX.
BS EN 61508 appears in the H.S.E.'s Approved Code of Practice for DSEAR, L138,1 as
well as BS EN 61511
1
See Paragraph 87 of 2nd edition of the Approved Code of Practice, L138
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Functional safety
management (“FSM”)
Sub-standards, such as IEC61511 for the process industries, reference
the master standard IEC61508. So one cannot “do” IEC61511
without IEC61508 as well.
FSM appears in the master standard in the normative Part 1 at clause 6
FSM also appears in each of the sub-standards
(For example FSM appears in IEC61511 for the process industries at Part 1 clause 5 )
Many of the Process Safety Management guides are not mandatory so
we will use the Energy Institute guidance as an example.
… so let’s compare them in the following slides:
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FSM vs PSM
CASS 32 is the FREE system for Functional
Safety Management.
The Energy Institute produced a “High level
framework for process safety management”
These are the two schemes used to enable
the comparison.
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FSM vs PSM
CASS 32 ref:
E.I. Guide ref:
The requirements of the
safety management:
Part 3 item 1 Functional
Section 1.2, Scope and
application
Policy:
Part 3 item 2 policy
Element 1 item 1.1 to 1.4
inclusive
Organisation and
responsibilities:
Part 3 item 3 organisation,
The relevant lifecycle
phases to my work:
Part 3 items 4 and 5
Element 1 item 1.5 to
1.15 inclusive
Techniques and
measures
conformance plan:
Part 3 item 6 Techniques &
Non-conformance plan:
Part 3 item 7
safety management
structure & responsibilities
Relevant lifecycle phases and
relationship with structure &
policy
measures
Nonconformance plan
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Element 2 all items
Element 6, 7 and 8, all
items
Element 10, 11 and 12.
See particularly 11.7
FSM vs PSM
CASS 32 ref:
E.I. Guide ref:
Competence
assessment:
Part 3 item 8 competence
Element 3, particularly
element 3.2 to 3.5
inclusive.
Procedure for handling
hazardous incidents
and near misses:
Part 3 item 9 hazardous
assessment process
incident procedure and
handling near misses
Element 6, particularly
element 6.10 to 6.15
inclusive, and
Element 19 all cases.
The lifetime of the safety Part 3 item 10 Procedure for Elements 16 and 17, all
operating and maintenance
trip - Operating and
cases
analysis
Maintenance
Part 3 item 11 Functional
Audit
Element 20 all cases
Safety audit process
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FSM vs PSM
CASS 32 ref:
Change management:
E.I. Guide ref:
Part 3 item 12 modification Element 8.4 and
process for safety systems
Maintaining information Part 3 item 13 maintaining
information on hazards from
from sources outside
industry
work:
Element 12 all cases
Not fully covered
Configuration
management:
Part 3 item 14 configuration Element 13 all cases
Training:
Part 3 item 15 training
Emergency services
plans:
Part 3 item 15 emergency
Review of safety
management
Part 3 item 16 formal
management procedures
services
reviews
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Elements 3.9, 3.11, 4.4
and 4.5
Element 14
Element 1.15, and at
the end of each
element
Conclusion
Functional Safety Management and Process Safety Management are
largely the same.
Functional Safety Management is mandatory.
FSM appears in the master standard in the normative Part 1 at clause 6
FSM also appears in each of the sub-standards
(For example FSM appears in IEC61511 for the process industries at Part 1 clause 5 )
Many of the Process Safety Management guides are not mandatory so
we have used the Energy Institute guidance as an example.
… so comply with FSM and add what is necessary for
other safety management schemes.
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