Safety Function Monitoring (Exaquantum/SFM)

Industrial processes regardless of complexity and size of safety systems and equipment require an ongoing assessment of their safety performance. A means to oversee and track these systems is an effective method of satisfying this requirement and if implemented correctly, can meet the needs of technical authorities and regulatory bodies.

Exaquantum/SFM collects all safety related data to keep track and analyze key safety performance metrics including, Safety Instrumented Functions (SIF) activations, Independent Layers of Protection (ILP), initiating causes and overrides.

By accessing this safety performance data, the information provided can assist plant managers in the monitoring of safety performance, identify any potential safety issues, reduce unnecessary maintenance activities and improve the overall safety solution design.

Exaquantum/SFM Overview

Exaquantum Safety Function Monitoring is a management tool developed to monitor safety performance in response to the growing pressure from regulations and legislation regarding safety reporting and assessments. Exaquantum/SFM collects, processes and presents safety data to enable monitoring and analysis of key safety KPIs such as SIF (Safety Instrumented Functions) activations, ILPs (Independent Layers of Protection), initiating causes and overrides. This information assists users to:

  • Verify operational safety performance
  • Identify safety gap
  • Optimize maintenance activities
  • Optimize safety solution designs

           Improvement of plant safety and availability throughout safety life cycle

 

  • Increased user efficiency and accuracy by quickly identifying safety events such as SIF Activations, Overrides/Inhibits and Protection Layer Availability
  • Improved and preventative planning of maintenance activities by identifying SIF Activation test results as replacements for scheduled tests
  • More efficient testing by marking devices that have actuated which could be used as scheduled test replacements
  • Improved identification of possible safety issues by active benchmarking of safety performance against design expectations
  • Reduced risk by identification of issues not recognized in the safety design
  • Reduced effort for generation of safety design validation information to support activities of regulators and technical authorities
  • Improved user capability by providing access to relevant information contained in a single database

           

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  • Overviews of the key safety KPI information including SIF activations by category, SIF output failures (devices), overridden SIFs and active ILPs
  • Verification of LOPA (Layer of Protection Analysis) through mapping SIS (Safety Instrumented Systems) elements against the LOPA 'Initiating Cause' assumptions
  • SIF device(s) activation monitoring
  • Non-SIF device(s) actuation monitoring
  • Override/Inhibit monitoring
  • Dynamic reports that can be periodically generated and exported

       

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SFM is an integrated, plant-wide solution for Safety Monitoring that:

  • Provides an analysis and reporting tool to help users monitor the performance effectiveness of defined SIS (Safety Instrumented Systems) against their design targets
  • Integrates data from the safety systems, control systems, and risk analysis from HAZOP, LOPA, etc.
  • Displays and reports to identify abnormal events and causes, or safety activations suitable for test replacement, which would not be possible without extensive manual analysis
  • Can be used to intelligently monitor and validate the correlated information, independent of system vendor

       

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Data Collection
The underlying Exaquantum historian provides Exaquantum/SFM with a powerful, integrated, cost-effective platform for collecting and storing data from different sources via OPC DA, OPC A&E and OPC HDA independent of the system vendor. OPC HDA has been expanded within Exaopc (Yokogawa’s OPC server) to allow historical Alarms & Events to be recovered following a communications interruption.

Risk Assessment (HAZOP, LOPA)
Exaquantum/SFM is configured with the safety design expectations derived from the HAZOP and (if conducted) LOPA risk assessments. This information is compared against the actual operational safety function activity that assists users in highlighting issues, helping to support the validation of safety demand rates and can help to optimize test scheduling. These findings can then be checked and verified against the base data within the defined SIS.

Web User Interface
Exaquantum/SFM provides secure web based displays and reports for user access from local or remote locations and does not require any client software to be installed.

SIF KPI’s
An overview of user filtered SIF KPIs is provided, allowing users to monitor and view the following information:

  • SIF Overview by Safety Integrity Level
    • Number of SIFs
    • Number of SIF activations
    • Number of SIF output faults (device failures)
  • ICSS (Integrated Control and Safety System) ILP Overview by Integrity Level showing both the number of currently inactive and user filtered date/time inactive ILPs
  • MOS (Maintenance Override Switch) Overview by Integrity Level showing both the number of SIFs currently in Maintenance Override and user filtered date/time SIF Maintenance Overrides

Identification of SIF Activations
Exaquantum/SFM provides comprehensive Alarm & Events monitoring capabilities to assist management in the identification of SIF Activations. These activations are then converted into Reports, Overview screens and SIF Activation lists, all of which provide users with a clear picture as to which SIFs have activated, and more importantly, which activations can be assessed and verified against the SIS base data.

SIF Activation Analysis
When SIF Activations take place, Exaquantum/SFM records key associated data that can be used to better understand the effect of the activation.

Exaquantum/SFM records the following information:

  • Associated safety device transitions and travel times to determine the travel times of the devices when activated, versus the expected design times as defined in the safety design
  • Related process information (pressure, temperature, etc.) is recorded and trended before, during and following the activation. This process information can be compared against baseline data to show variations in the profile signature of any process data deviations
  • Actuating device starts and stops are overlaid onto process data trends making it easy to view changes in trends before and during device transitions

SIF Activation Verification
Exaquantum/SFM can be used as a mechanism to show which SIFs have been activated, which can then be verified against the SIS base data. This verification process establishes the SIF Activation reason(s), which is also known as the ‘Initiating Cause’. The Initiating Cause(s) are derived from the safety design and imported into Exaquantum/SFM. When an Initiating Cause has not been identified in the safety design, Exaquantum/SFM allows a new Initiating Cause(s) to be defined that is displayed in various Exaquantum/SFM reports. These reports can verify against the safety design to initiate improvements.

Initiating Causes
SIF Initiating Causes are monitored against the safety design. This provides a valuable understanding of the actual demand versus the expected demand. The Exaquantum/SFM traffic light system provides users an early warning sign when Initiating Causes have exceeded their expected design frequency.

Monitoring Overrides and Inhibits
Exaquantum/SFM monitors SIF overrides, inhibits and their protection layers. This provides critical information in the understanding of SIFs having sufficient protection and are maintaining their designed SILs.

Safety Reports
Exaquantum/SFM provides dynamic reports for all information displayed on the web interface with the ability for users to select fields and drill into data as well as filtering and sorting by almost all fields being displayed.

Reports contain SIS information for the following areas:

  • SIF Activations
  • ILP Availability
  • Device Actuations
  • Overrides and Inhibits
  • Initiating Causes
  • SIF Masking

Reports can be exported to multiple formats (such as Excel, Word and PDF) and scheduled to be emailed at configurable periods.

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