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Functional safety in the process industry

Functional safety in the process industry The process industry places the highest demands on safety and availability. Phoenix Contact will support you in the implementation of IEC 61511 with certified solutions and comprehensive expertise.

When planning, setting up, and operating safe process plants and machines, current directives and laws provide the framework to be observed. These standards reflect the minimum state of the art of technology that is to be adhered to. The IEC 61511 series of standards governs the application of the functional safety of systems in the process industry.

The planners, manufacturers, and operators of systems are just as responsible for implementation as the system integration department that implements functional safety. Amendments to the requirements require regular adjustment to verification documents, processes, and employee training. Modifications and integration of subunits into existing systems make continuous checks necessary.

We provide:

Safe components for safety applications in process plants, certified in accordance with IEC 61508 and IEC 61511
ATEX-certified, robust safety technology for use in potentially explosive environments
Safe diagnostics and easy proof test in accordance with IEC 61508

Applications

The process industry deals with a wide range of potential hazards for humans, property, and the environment. To minimize these risks, operation and regulation functions maintain the process control engineering sequences. Systems are protected with integrated safety technology systems.

Level monitoring

Safe solutions for overflow protection.

More about fill-level monitoring

Industrial thermoprocessing technology

Our solutions ensure lower emissions, maximum safety security, and intelligent protection through the IIoT for a sustainable and future-oriented production system.

More about industrial thermoprocessing technology

Products

For functional safety applications in the process industry, Phoenix Contact provides a wide range of SIL-certified products, from safe coupling relays to safe controllers.

Safe coupling relays

Safe coupling relays for special applications in the process industry.

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Configurable safety systems

As easy to use as a safety relay and as flexible as a safety controller.

More about configurable safety modules

Safe I/Os

Safe I/Os for the control cabinet and field installation.

More about I/O systems

Safe control technology

Modular and powerful: safe control solutions for your application.

More about PLCs

Safe signal conditioners

Signal conditioners with functional safety and explosion protection.

More about signal conditioners

Safe power supplies

High-performance power supplies for maximum operational safety.

More about power supplies

Standards and directives Requirements for designing protective functions in the process industry

There are special design guidelines with respect to functional safety when it comes to the fundamental requirements for safe operation of systems in the process industry. The internationally harmonized procedure for PCE safety equipment is described in IEC 61511. A significant part of this procedure is the safety lifecycle in conjunction with functional safety management. The individual phases of the procedure are highly interdependent and make it possible to consider all requirements over the entire lifecycle of the safety equipment.

Safety lifecycle Information for planning, system integration, and operation

Safety lifecycle for system planning

Safety planning
Planning of the activities that are required for achieving functional safety (FS) of the system, including verification and validation.
Risk assessment
Systematic identification and evaluation of all risks and establishment of measures to be taken for adequate risk reduction.
Assigning protection layers
Assigning the planned measures to individual protection levels and establishing the required SIL for safety functions.
Functional safety management
Establishing a management system for controlling the safety lifecycle and for resource planning.
Evaluating functional safety
Recurring assessment of whether the safety planning and functional safety management were applied correctly.

Safety lifecycle for system integration

Specification of safety requirements
Specification of the requirements for the safety system including the safety functions.
Validation planning
Planning of the necessary activities for checking the specified safety functions.
Design and planning of the safety system
Detailed planning of the implementation of the safety requirements and the safety functions, validation of the safety integrity.
Assembly and startup
Installation of the safety system and commissioning.
Validation
Implementation of the function test based on validation planning and providing evidence of adequate risk reduction in accordance with the risk assessment.

Safety lifecycle for plant operation

Operation and modification
Maintenance of the functional safety during operation and in the event of system modifications.
Decommissioning
Deactivation and complete removal of safety functions that are no longer necessary.

Process reliability Compliance with current legal requirements

In the process industry, there are different potential hazards for people and the environment. To minimize these hazards, the requirements from IEC 61511 should be met. IEC 61511 provides for functional safety management to prevent systematic errors. To control random errors, the safety functions must be designed correctly. In addition, the requirements of explosion protection must be observed. Increasing confinement due to legislation and the growing number of safety regulations require an understanding of the fundamentals of explosion protection.

The way to a safe process plant Implementation of functional safety management

The safety lifecycle illustrates the process:

A detailed and well-documented risk analysis is the foundation for producing a safe process plant. Based on this, the following documents can then be created in the individual phases:

Safety Requirements Specification
Design of the hardware and SIL assessment
Software documentation
Validation of the safety functions

If these phases are passed through without planning and without a suitable management system, systematic errors can creep in. These errors may go undetected until a hazard occurs. Therefore, the path to a safe process plant starts before the risk analysis (incl. HAZOP). To avoid systematic errors during the individual phases, plant manufacturers and operators need a functional safety management system.

Video series

Functional safety in the process industry

What does HAZOP stand for and what is an interlock function? Manuel Ungermann, Safety Product Manager at Phoenix Contact, explains terms, topics, and products related to safe switching on and off in process engineering systems.

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FAQs Frequently asked questions about safety of machinery

1. What is IEC 61511?
IEC 61511 is an international standard that defines requirements on functional safety in the process industry. It regulates the entire safety lifecycle of safety-related systems such as Safety Instrumented Systems (SIS).

2. Which industries is IEC 61511 relevant for?
The standard is aimed at organizations operating in the process industry, such as chemicals, pharmaceuticals, oil and gas, food production, and water/wastewater management companies.

3. What is the difference between IEC 61508 and IEC 61511?
IEC 61508 is the overarching standard for functional safety in all industries. IEC 61511 is an industry-specific derivation for the process industry and is based on the principles of IEC 61508.

4. Which Phoenix Contact products comply with IEC 61511?
Phoenix Contact products that comply with IEC 61511 include safe coupling relays, signal conditioners, VIP I/O marshalling products and ATEX-certified components, among others.

5. How does Phoenix Contact support the implementation of IEC 61511?
In addition to certified products, Phoenix Contact also provides training courses, webinars, and tailored advice on the standard-compliant implementation of functional safety in the process industry.

6. What is SIL (Safety Integrity Level)?
SIL describes the reliability of a safety-related system. IEC 61511 defines four SIL levels, with SIL 4 being the highest safety level.

7. What happens during an emergency shutdown (ESD)?
Emergency shutdown is the definition for a safe shutdown in the event of danger. When emergency situations occur in process plants, the protection of people and the environment has the highest priority. To minimize hazards, immediate shutdown of the affected systems is required, among other things. In such a case, the emergency shutdown (ESD) system intervenes. Safe coupling relays from Phoenix Contact safely switch off affected applications in an emergency.

8. What are Fire-and-Gas systems?
The term Fire-and-Gas signifies that warning systems will be activated at an early stage. In the process industry, a Fire-and-Gas system is required in addition to an emergency shutdown system. It is necessary to issue an early warning of the danger in the event of a fire breaking out or explosive gases escaping. Safe coupling relays from Phoenix Contact reliably switch on sirens and warning lights in an emergency.