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ISA Division Newsletter
                                                                                         Safety
                           Summer 2005
                         Brian Smith, Editor                                           Division
                                   Director’s Message
                                   By Edward M. Marszal, PE, CFSE


                                   Dear ISA Safety Division Member,
                                       I am very flattered to have been nominated and approved as Director
                                   of the Safety Division of ISA. I am very excited about this opportunity
                                   and have big plans to expand the membership of the Division by providing
                                   Member benefits that will make the Division a “must have” resource for anyone who is
                                   involved with engineering instrumentation containing safety aspects. Some of the plans involve
                                   expanding the scope of the Division to cover all facets of instrumentation design that have
                                   a safety critical impact. This might include such tasks as alarm system design, alarm
                                   rationalization, and security considerations for safety instrumented systems (SIS).
                                       I firmly believe that in order to make our Division a success we need to provide benefits that
                                   cannot be obtained in any other place. We have had a great start under Paul Gruhn, when we
                                   established a Division Symposium that has become a must-attend event for safety practitioners,
                                   and a Web site (www.isa.org/divatsafety) that contains loads of information that is not available
                                   anywhere else. We hope to renew these events starting in Spring 2006. I’d like to continue this
                                   path by continuing to expand the value and size of safety-focused conferences and adding more
                                   to the Web site sections that are only viewable by Division Members. I’d like to see the Web
                                   site expand from providing the papers of past safety conferences (which is an excellent start) to
                                   providing electronic tools and data for performing safety lifecycle tasks. This could include
IN THIS ISSUE:
                                   tutorial presentations in PowerPoint, MPEG, or Flash format, spreadsheet tools for performing
                                   SIS related calculations, and submittals of actual proven-in-use field data from end users for
Director’s Message      1          various types of equipment. These tools, along with the ability to share ideas and debate tech-
                                   niques, both electronically and during conferences, will make Membership in the Division an
Past Director’s Message 2
                                   indispensable tool.
Safety Instrumented Burner             I am also very pleased to announce the 2005 slate of officers and sub-committee chairmen,
Management Systems —               along with a new line-up of subcommittees.
Ready or Not Here
They Come!               3         STAFF SUPPORT:            Rodney Jones, ISA, (919) 990-9418, rjones@isa.org

Application Software               VOLUNTEER STAFF:          Position                   Name                     Company
Fault Analysis          4                                    Director                   Ed Marszal               Kenexis
                                                             Director-Elect             Bud Adler                AE Solutions
API Standards and
                                                             Program/Member Chair       Carl Sossman (Acting)    WSMS
Recommended Practices
                                                             Webmaster/Newsletter       Brian Smith              Nova Chemicals
for Offshore Facilities 6
Alarm Management for               SUBCOMMITTEES:            Burner Management Systems
Safety Alarms        6                                       Chair               Mike Scott                      AE Solutions
                                                             Chair-Elect         Kevin Maki
Book Reviews            7
                                                             Control Systems Security
                                                             Chair                   David Teumim                Consultant

                                                             Fire and Gas Protection/Detection
                                                             Chair                   Charles Fialkowski          Siemens
                                                                                                                  continued on page 2
Safety Division Newsletter • Summer 2005                                                                                                  Page 2



SUBCOMMITTEES:     (continued)   Nuclear Safety
                                 Chair                    Troy Martel                                Past Director’s Message
                                 Offshore Safety                                                             Paul Gruhn, PE, CFSE
                                 Chair           David Haysley          Albert-Garaudy Associates         Safety Division Past Director
                                 Chair-Elect     C.R.Ragu               ONGC
                                                                                                                        I’m pleased to inform
                                 Safety Instrumented Systems (Safety PES)
                                                                                                                        you that the Safety
                                 Chair          Andrew Dennant      Emerson
                                                                                                                        Division won three
                                                                                                                        awards in 2003:
                                 Safety Field Equipment
                                                                                                                        • Outstanding Divi-
                                 Chair           Bill Goble             exida.com
                                                                                                                          sion — Honorable
                                 Alarm Management
                                                                                                                          Mention
                                 Chair       Chris Wilson               TiPS                                            • Most Improved
                                                                                                                          Division
   For anyone who is considering                     risk-based inspection consulting. In his       • Division Communications Award
becoming active in the Division, it is a             current position, he has experience in SIS         (tied with the Analysis Division)
very satisfying and rewarding experi-                implementation and process safety man-             We were the ONLY Division to win
ence. If you see a sub-committee that                agement projects for a variety of process      three awards! A total of three other
does not have a chair-elect and would                plants in diverse world-wide locations.        Divisions won two awards each. We’ve
like to participate, please let me know.             Marszal received a B.S.Ch.E. from Ohio         accomplished a lot in just two years and
Also, we are looking to give Carl                    State University in 1992 with emphasis         have much to be proud of! It wouldn’t
Sossman, who has been working tire-                  on control systems and artificial intelli-     have been possible without the work of
lessly for the Division, a break from has            gence. After receiving his degree he           all of our board members. I am especially
seemingly endless responsibility for pro-            joined UOP, a licensor of process units to     grateful to Brian Smith (our Newsletter
gram direction with a fresh recruit. I               the petroleum and petrochemical indus-         Editor/Web Master) and Carl Sossman
have some ideas, but if you would like               tries, where he performed field verifica-      (our 2003 Program Chair). The fruits of
to throw your hat in the ring for this               tion of control and safety instrumented        their efforts are the most visible and
high-profile position, please let me                 systems at customer sites, and designed        require the most work.
know.                                                and managed development of custom                  I have completed my two-year term as
   I am looking forward to a great year              control and SIS projects. After leaving        Division Director. Erwin Icayan will now
with the Division getting back on track              UOP he worked with ERM-Risk, a risk            take over as Director. Ed Marszal will be
in terms of growth and programming.                  management consulting firm specializing        the next Director-Elect. I can’t think of
For those of you who don’t know me,                  in risk analysis and process safety man-       two more qualified and capable leaders.
I’ve included some bio information                   agement. In this position he performed             A number of the subcommittees are
below. Please feel free to call or write to          and managed risk assessment projects           changing faces as well. Butch Taggart
discuss any questions or comments you                that included quantitative analysis.           (Offshore Safety) will be passing over his
have about the Division, or safety                   Recommendations from these projects            chair to Don Ogwude. Don is a consult-
instrumented systems in general.                     were used to ensure regulatory compli-         ant who spent many years with Chevron
                                                     ance, justify risk reduction expenditures      in California and is a member of the ISA
Edward M. Marszal, PE, CFSE                          and optimize insurance coverage. He            SP84 committee. Mike Scott and Kevin
President, Kenexis Consulting                        teaches many of the Kenexis courses on         Maki will be swapping their roles as
Corporation                                          process safety management and safety           chair and assistant in Burner Management
Phone: (614) 451-7031 ext. 1                         instrumented system design and analysis.       Systems. Simon Pate will be passing his
Fax: (614) 451-2643                                  He also regularly lectures on loss preven-     chair position in Fire & Gas Systems over
Mobile: (614) 226-4263                               tion topics at Ohio State University.          to Robert Seitz. Robert is a PE in Alaska
E-mail: edward.marszal@kenexis.com                   Marszal peer reviews papers for ISA            who specializes in such systems and serves
http://www.kenexis.com                               Technical Conferences and ISA                  on several standards committees.
                                                     Transactions, and is the author of the         Palaniappan Kannan will serve as our
BIO: Mr. Marszal has over twelve years               award winning ISA book Safety Integrity        2004 Spring Program Chair. Kalpen
of experience in safety instrumented sys-            Level Selection. He is active in ISA at the    Vachharajani will serve as our 2004 Fall
tems design and risk analysis. He is                 local and national levels, holding several     Program Chair.
President of Kenexis Consulting                      positions with the ISA Columbus Section,           Division board members have discussed
Corporation and responsible for engi-                of which he is currently Vice-President,       the idea of having Security receive a
neered safeguards design basis consulting            and as a member of several safety related      much higher profile within the Division
including: safety instrumented system                standards committees, including SP84,          (than it’s current subcommittee status).
implementation projects, process hazards             SP91, and SP18. He is a registered pro-        We discussed this with the Chair of our
analysis, quantitative risk analysis, alarm          fessional engineer in Ohio and Illinois        Security Subcommittee and certain mem-
management and rationalization, pres-                and also a TÜV certified functional safe-
                                                                                                                        continued on page 3
sure relief valve and system surveys, and            ty expert.
Safety Division Newsletter • Summer 2005                                                                                       Page 3




                            Safety Instrumented Burner Management Systems
                                      Ready or Not Here They Come!
                                        Michael D. Scott, P.E., Safety Division BMS Chairman
                              VP – Process Safety, AE Solutions, P.O. Box 26566, Greenville, SC 29616

   The concept of a Safety Instrumented          • EN 50156-1 – A German standard                • FM Representative
Burner Management System (SI-BMS) is               covering electrical equipment for             • NFPA 85/86 Representative
here to stay. If you are unsure of this            furnaces that is scheduled for                • ISA SP84 BMS Sub-Committee
statement one should consider that six             revision in 2004. This document                 Member
different codes/standards currently exist          invokes SIS requirements for a                • Process Industry End Users
and/or are being revised to invoke the             BMS.
Safety Lifecycle with respect to Burner          • API 556 – Document governs
Management Systems. This includes the              design of BMS’s in the petroleum
following:                                         industry. Is being revised to invoke
   • The Black Liquor Recovery Boiler              SIS requirements on BMS’s.
      Advisory Committee (BLRBAC)
      has developed several guideline            To promote the SI-BMS concept, ISA
      documents regarding design and          has developed a Web seminar and is in
      operation of Recovery Boilers in        the process of introducing a one-day
      the Pulp and Paper Industry. These      course on this topic. The schedule for the
      documents invoke SIS requirements       next BMS-related training is as follows:
      on the Recovery Boiler BMS.                • Is a Burner Management System a
   • FM 7605 – Factory Mutual                      Safety Instrumented System? Web
      requires that any PLC listed for use         seminar 14 July 2005 & 16
      in combustion safeguard service              November 2005
      meet the SIS requirements con-             • Safety Instrumented — Burner
      tained in IEC 61508. At this writ-           Management Systems: A How To
      ing we are aware of only one ven-            Primer One-day seminar (Dates to
      dor who has a product submitted              be announced in the near future)
      to FM for approval with respect to
      SI-BMS.                                    If the above subject is of interest to       Check out this
   • SP84 – The ISA SP84 committee            you, or if you have other intriguing            informative book
      has formed a BMS sub-committee          questions regarding BMS designs, the
      to develop a document that clari-       Safety Division provides an excellent           from ISA.
      fies how SIS concepts apply to a        forum to search for answers. This can           Go to www.isa.org/
      BMS. Examples being included in         be accomplished in three ways:
                                                                                              safetyreliability for more
      the document for each code or              1) Join the Safety Bulletin Board and
      standard are:                                 post your BMS questions for the           information on this and other
      • NFPA 85 – Single burner boiler              Division members to answer.               safety-related books from ISA.
      • NFPA 86 – Thermal oxidizer               2) Plan on attending ISA EXPO 2005           Read a review of this book
      • API 556 – Process heater with               in Chicago. A BMS paper session
         multiple burners                           and/or panel session is planned to        on page 7.
      • API 14C – Reboiler                          address this subject. Contact Mike
      • API 14C – Heater Treater                    Scott if you wish to present papers
         The goal of the SP84 committee             and/or participate in a panel session
      is for industrial users to properly           on BMS designs.                         Past Director’s Message
      follow the safety lifecycle to define      3) The ISA EXPO 2005 panel session         continued from page 2
      the risk associated with every BMS            will provide a forum for the audi-
      to determine if it is a SIS.                  ence to ask questions of industry       bers of the SP99 security standard com-
   • NFPA 86 Committee is planning to               experts on the design and applica-      mittee. ISA has already had at least two
      update this standard to reflect their         tion of BMS’s. The goal of this         Security Conferences. It would make
      agreement that an industrial BMS              panel session is to review NFPA         sense for both groups to join forces and
      is a SIS and that a safety PLC                requirements for BMS’s and com-         take advantage of the synergy. Perhaps
      should be used. A linking para-               pare/contrast these issues with the     we may change our name to the Safety &
      graph will be added that refers to            requirements of SIS standards (i.e.     Security Division. Stay tuned for where
      ANSI/ISA-84.00.01-2004 as                     ANSI/ISA-84).                           Erwin may lead us in this area.
      acceptable methodology.                       • Proposed Panel Session Members           It’s been a pleasure serving with you.
Safety Division Newsletter • Summer 2005                                                                                             Page 4




                                           Application Software Fault Analysis
                                                        Palaniappan R. Kannan
                                    SISRA Consultants, Singapore 650319, Rmp66@singnet.com.sg

Abstract                                       are the ones that can be used effectively         • Improper handling of data types
    A Programmable Electronic System           and when they should be used in the               • Truncation and rounding off errors
(PES) consists of both hardware and            process of software development. This             • Improper handling of abnormal
software. Hardware failures are pre-           requires knowledge about the software               conditions
dictable whereas software faults and           faults that occur in the first place, which       • Calculation overflow
failures are not. These software compo-        needs to be categorized in order to
nents are what make PESs more com-             understand the problem areas.                      Variable Initialization: The initial val-
plex. The only way to address software            The major categories of application         ues assigned to variables at the start and
related failures in PESs is through imple-     software faults are:                           re-start of program execution need to be
mentation of proper development                   • Calculation                               error free for the proper execution of
process, programming methods and rig-             • Variable Initialization                   the programs and resulting outputs. In
orous testing. This article will review           • Timing Synchronization                    case of hardware or processor redun-
various types of faults that can occur in         • Interface                                 dancies, the variable values should
application software development.                 • Change Impact                             transfer correctly for proper continua-
                                                  • Omission/Commission                       tion of their succeeding runs. Counters
Introduction                                      • Configuration Management                  and timers also need to be considered.
    Application software is one of the            • Data                                      Typical problems found in variable ini-
components that contributes to the                • Requirement Specification                 tialisation are:
unavailability of a PES. Software failures        • Logic                                         • Lack of, or incorrect, initial values
are one type of systematic failures that                                                            when programs start or restart
reside inside the system as built in faults.      Calculation: Calculation errors can be          • Initial or present value storing and
In order to avoid software based failures      due to programming the algorithm/for-                transfer problems for succeeding
of a system, it is important to identify       mula incorrectly or computational errors.            runs and hardware transfers
and rectify all the software faults during     Types of registers, their addressing meth-
the various phases of its development.         ods, and the way the processor handles            Timing Synchronization: This factor
Many software faults are not self-reveal-      the floating-point values are different for    comes into play when there is real time
ing. Also, unlike hardware failure rates,      different systems. Proper understanding        execution of software processes and
software failure rates are not predictable     of these points is essential. Typical prob-    when different processes executed in dif-
and cannot be accurately quantified.           lems found in calculation faults are:          ferent domains need to interact.
Failure rates cannot be used effectively          • Incorrect coding of constants             Depending on the points of interaction
to determine safety integrity levels.             • Improper handling of boundary             this can affect data acquisition, code
    There are many reasons for software-             conditions                               execution, system functioning, and/or
related failures. These range from poor
development processes, application
                                                                                                                        Software
complexity, interaction between mod-               Software                                                             Validation
ules, poor personnel competence, vari-             Requirement                                                          Testing
                                                   Specification
ability, and use of off-the-shelf software.

Software Development Process
   The first step in avoiding software                       Software
faults is to follow a good development                       Architecture                                     Software
                                                             and System                                       Integration
process. The process should handle the                                                                        Testing
                                                             Design
complexity associated in the development
of software. Various standards recom-
mend the classic “V-model” (see Figure
1), which emphasizes modular develop-                                       Software
                                                                            Module                   Software Module
ment and testing each phase. Test plans                                                              Testing
                                                                            Design
and methods need to be established.

Software Faults
   There are numerous methods for               Figure 1: The V-Model
software fault prevention and detection.        of Software Development
However, it’s necessary to know which                                                   Software Coding
                                                and Testing
                                                                                                                    continued on page 5
Safety Division Newsletter • Summer 2005                                                                                       Page 5



continued from page 4                        configuration management procedures              Logic: Logic faults have their roots in
system outputs. Typical problems found       should be adopted throughout the soft-        requirements, design and/or code. Logic
in timing synchronization are:               ware lifecycle. Three areas that require      problems do not relate to phases, but
   • Interacting processes going out of      configuration management is required          rather to the whole development process.
      synchronization                        are documentation, hardware, and soft-        Competent personnel and their ability to
   • Inaccurate real time clock              ware. Software versioning tools are now       understand the requirements are key.
   • Non-occurrence of event due to          available as part of application develop-     Typical logic related problems are:
      timer failure                          ment. Configuration management also              • Faults due to incomplete or incor-
                                             helps to set responsibilities and account-         rect logic
   Interface: In order to perform its        ability and should be part of software           • Faults due to interaction between
functions and provide useful output the      development management. Typical                    various modules
system software needs to interface with      problems in configuration management             • Improper functioning during
other system devices and software.           are:                                               abnormal conditions and states
These can be inputs devices, outputs            • Selection of incompatible hardware          • Coding errors
devices, or other systems performing               and software
other functions. The requirement speci-         • Failure to upgrade other systems to      Conclusion
                                                   software changes                            This article reviewed various types of
fication should describe all interface
                                                • Use of incorrect master program          faults that can occur in application soft-
needs. All interfaces should be traceable
                                                   for software revisions                  ware development. Adopting a good
to the requirement specification. Typical
                                                                                           development process is of paramount
problems found in interfaces are:
                                                 Data: Faults can occur due to data        importance. It is important to identify
   • I/O interface errors
                                             types, units, range values, and acceptable    probable fault categories and the neces-
   • Calling of incorrect functions and
                                             change magnitude/frequency. Hardware          sary techniques that need to be used to
      sub-routine
                                             manuals should exist and should provide       avoid them. The identified fault cate-
   • Mistakes in passing of parameters
                                             details about the limitations in data codi-   gories and detection/prevention tech-
                                             fication. Programs should contain diag-       niques need to be assigned to various
   Change Impact: Software development
                                             nostic code to handle data faults, such as    phases of the development process. Once
contains many feedback paths. Revisiting
                                             data validation techniques. For example,      this is done, resources can be identified
earlier phases and making changes are
                                             all input data can have a valid range         and test cases can be prepared.
common. After all, software requirements
                                             specified, and if a value goes out of range       However, it is difficult to identify
are based on overall system requirements
                                             a diagnostic alarm can be triggered.          one’s own fault. This also applies to the
and changes in software requirements can
                                             Another way of avoiding data faults is to     software development team. Therefore,
also occur as the design progresses. Every
                                             use typed data tables. Typical data relat-    review by different competent persons
time a change is incorporated, the overall
                                             ed problems are:                              not belonging to the team can greatly
impact of that change should be studied
                                                 • System failure due to invalid input     help in fault finding. Assessment and
thoroughly. Typical problems due to
                                                   data                                    assurance can accomplish this.
change impact are:
                                                 • Problems in database data retrieval         Every software application is unique,
   • Inability to properly execute logic
                                                                                           and so are its faults and failures. Iden-
      and sequential function
                                                Requirements: The starting point of        tification of faults requires feedback
   • Incompatibility of existing systems
                                             software development is the requirement       from existing applications. Therefore,
      with changed device
                                             specifications. This is critical for the      fault related data collection from differ-
   • Loss of existing function
                                             completeness and correctness of the final     ent applications can be of great value in
   • Change not verified and validated
                                             product. Care should be taken to devel-       understanding the types of problems in
                                             op a correct requirement specification        specific application domains and devel-
   Omission/Commission: Anything
                                             which should deal with performance            oping prevention/detection techniques.
produced by human beings is subjected
to omission and/or commission errors.        requirements, functional requirements
                                             and interface requirements. Semi-formal       References
Software is no exception. These errors
                                             methods such as function block dia-           1. Functional safety of electrical/elec-
can result in missing required system
                                             grams, flow charts, truth tables, etc., can   tronic/programmable electronic safety-
functions and/or additional system func-
                                             be used in specifying various functions.      related systems, IEC 61508, 2000,
tions not required by system. System
                                             Verification and validation are key steps     International Electrotechnical
functional documents, which are
                                             to ensure that the software produced          Commission, Geneva, Switzerland.
required as part of the development
                                             complies with the requirements. Typical       2. Wallace, Dolores R., Laura Ippolito,
process, can also have omission and
                                             problems caused by requirement specifi-       and Barabara Cuthill, “Reference
commission faults. Typical problems
                                             cations are:                                  Information for the Software Verification
due to omission and/or commission are:
                                                • Unspecified exceptional conditions       and Validation Process,” NIST SP 500-
   • Missing (or) improper documentation
                                                   and states                              234, National Institute of Standards and
   • Missing specification requirements
                                                • Missing functions in the specification   Technology, MD 20899, April 1996.
   • Missing functions
   Configuration management: Good               • Unspecified testing requirements
                                                                                                               continued on page 6
Safety Division Newsletter • Summer 2005                                                                                        Page 6



continued from page 5
                                                        API Standards and Recommended Practices
Author Bio
   Palaniappan Kannan has 18 years of                             for Offshore Facilities
instrumentation, process, control and
safety system experience. He has                 To understand the needs of the                 • API RP 14G – “Recommended
worked in various phases of oil and gas       upstream segment facilities for the                 Practices For Fire Prevention and
and petrochemical projects in operation       petroleum industry, it is necessary to be           Control on Open Type Offshore
and maintenance, engineering, consul-         familiar with the basic standards that              Production Platforms”
tancy, and system integration.                are used. During the coming year, it is           • API RP 14J – “Recommended
   Palaniappan has a Bachelors degree in      the goal of the ISA Safety Division                 Practices For Design and Hazards
instrumentation and is a Certified            (Offshore Sub-Committee) to develop                 Analysis for Offshore Production
Functional Safety Expert (CFSE). CFSE is      and publish papers on some of the                   Facilities”
an accreditation by TÜV certifying com-       applicable API standards and recom-               As Chairman of this subcommittee, I
petency to implement Safety Instrument        mended practices that deal with safety         am requesting input on these documents,
Systems (SIS) in line with international      issues in the design, fabrication, installa-   or any other documents that would be
standards such as IEC 61508 and IEC           tion, and operation of this segment of         applicable. Details on any experience
61511. Palaniappan has a Masters degree       the petroleum industry. It is intended         with combining the requirements of these
in Business Administration (MBA) and is       that these papers will cover general safe-     API documents and the ISA/IEC SIS stan-
a certified Project Management                ty issues and, to the extent possible,         dards would be greatly appreciated. If
Professional (PMP-PMI).                       focus on BPCS, Fire and Gas Detections         you have papers, or want to develop a
   Palaniappan is actively involved in        Systems, and SIS. Co-ordination of these       paper, please contact us.
professional bodies like ISA and IEEE.        documents with the current ISA                    Also if you have any recommendations
He has published articles and developed       (ANSI/ISA-SP84.00.01) & IEC (IEC-              on other activities that our subcommittee
software tools in the SIS area. He is a       61511) standards will also be addressed.       should pursue, we would like to hear
committee member of ISA SP84-                    Preliminary Listing of Documents:           them.
Programmable Electronic System (PES)             • API RP 75 – “Development of
for Use in Safety Applications and ISA              Safety and Environmental                 Contact:
SP99 – Manufacturing and Control                    Management Program for Outer             David Haysley
System Security standard committees.                Continental Shelf Operations and         Albert-Garaudy and Associates, Inc.
   Throughout his career Palaniappan                Facilities”                              3500 N. Causeway Blvd.
has been involved in HAZOP studies,              • API RP 14C – “Recommended                 Metairie, LA 70005
developed SIS specifications, engineered            Practice for Analysis, Design,           (504) 846-6466
SIS systems, performed SIL verification             Installation and Testing of Basic        Cell: (504) 231-5262
calculations, and developed SIS func-               Surface Safety Systems for               dhaysley@aga-engineers.com
tional testing procedures.                          Offshore Production Facilities”



                                      Alarm Management for Safety Alarms
   At ISA EXPO 2004 last year, I had          similar to a HazOp study. Some support         imize the possibility of a mistake when
the opportunity to sit down and discuss       a more simplistic view, a “lightweight”        removing or changing alarms, consider
a growing concern that current trends in      version of alarm management that does          the mass of alarms that were added
“alarm management” ignored the safety         not involve the paperwork, personnel,          without any formal review.
ramifications of changing the alarm sys-      resource overhead of a “HazOp-style”              Alarm management projects are
tem. The conversations centered on the        alarm management project.                      intended to remove the smoke from oper-
loss of safety related alarms due to             People who support a more compre-           ators’ eyes. How much of that smoke was
incomplete or arbitrary reviews prior to      hensive approach to alarm management           arbitrarily implemented? Perhaps if we
the removal or modification of alarm          almost always focus on the process of          embraced a HazOp-style process of alarm
system settings. Emphatic points were         removing alarms. Don’t doubt that a            system design and of controlling changes,
made in support of a safety-centric           holistic review and redesign of an alarm       we can prevent the need for massive
review process, or at least for the inclu-    system can be a painful proposition.           alarm redesign projects in the future.
sion of HazOp information during the          There is no magic button that can
review process.                               reverse what has already become a              Chris Wilson
   Many involved in defining what alarm       problem, but there is a way to prevent         Marketing Manager
management is embrace a safety oriented       the problem in the future.                     TiPS, Inc.
viewpoint and feel that it aligns well with      Alarm management exists because             (512) 863-3653 x 520
their already established opinion that the    alarms have gone out of control. Some          chris@tipsweb.com
process of alarm management should be         level of due diligence is required to min-
Safety Division Newsletter • Summer 2005                                                                                       Page 7




                                                         Book Reviews
                                              FMEDA data and many product specific         and control manager. The shift of control
                                              entries based on specific FMEDA data         systems from proprietary to commercial-
                                              from TÜV, FM, exida and others.              off-the-shelf hardware and software and
                                                 The handbook can be purchased             network connectivity have created new
                                              through the following three sales            vulnerabilities in industrial networks. But
                                              channels:                                    cybersecurity alone is not enough. A
                                              • exida.com online store                     complete security program also includes
                                              • ISA online store, www.isa.org/books        personnel security, and physical security.
                                              • Amazon.com                                     Cybersecurity consists of protecting
                                                                                           the availability, integrity, and confiden-
                                                                                           tiality of the systems and data. This
Safety Equipment Reliability                                                               requires understanding the threats to the
                                                                                           systems and the vulnerabilities of the
Handbook                                                                                   systems. Threats like the Slammer worm
Published by exida.com                                                                     and buffer overflows are explained.
ISBN: 0-9727234-0-4                                                                        Some of the highlights of this book are
                                                                                           the examples of real attacks on control
    Are you performing Safety Instrumented                                                 systems and the consequences.
Function verification calculations?                                                        Countermeasures can be designed to
Regardless of what method you are using                                                    protect against the threats. Usually a
– Simplified Equations, Reliability Block                                                  system for identification, authentication,
Diagrams, Fault Tree Analysis, Markov                                                      and authorization is one of the most
Modeling, or a commercially available                                                      important layers of defense.
tool – you need failure rate and failure                                                       The remainder of the book covers the
mode data. The exida Safety Equipment
                                              Industrial Network Security                  steps, at a very general level, to execute
Reliability Handbook contains the infor-      By David Teumim                              an industrial network security program.
mation you are looking for.                   Published by ISA                             The first step is planning and design for
    The exida Safety Equipment                ISBN: 1-55617-874-3                          security, such as separation of networks.
Reliability Handbook was officially                                                        An understanding of the technology, like
released in March 2003. The handbook          The ABCs of Network Security                 encryption and firewalls is important.
was created to solve one of the major         Reviewed by Nick Sands                       To make an effective security system
problems when implementing Safety                One of the hottest topics in the con-     requires writing clear policies for the
Instrumented Function verification cal-       trol industry is security for process con-   application of technology, trained and
culations, i.e. getting failure rate and      trol systems and networks. Finally ISA       aware people, and periodic audits and
failure mode data. The handbook was           has a book on the subject: Industrial        other methods to provide assurance of
created to supply that information in a       Network Security by David Teumim.            the effectiveness of the security pro-
format specific to safety integrity verifi-   Teumim is a certified information system     gram. Some example approaches to
cation and to allow for easy comparison       security professional (CISSP) and a          industrial network security programs
between equipment items or designs on         workgroup leader for SP99, the commit-       from Dupont and Proctor & Gamble
failure rates, failure mode distributions,    tee working on manufacturing and con-        form the last chapter.
and diagnostic detection capability.          trol system security. The book is very           Every company in the control commu-
(This is the primary difference between       basic – an introduction to an introduc-      nity will have people that can benefit
the exida handbook and other more             tion on the subject. But with such a new     from reading this book, people that need
generic reliability data sources, such as     area, this elementary book is a good         a basic understanding of information
OREDA – Offshore Reliability Data,            beginning to the body of knowledge.          security for manufacturing and control
AIChE, IEEE, and others.)                        The first chapters are an introduction    systems. Teumim just introduces the sub-
    It contains data on a wide variety of     and background, answering many ques-         ject though, with little detailed informa-
safety-related equipment, such as pres-       tions. What is an industrial network?        tion. Future books or revisions of this
sure transmitters, temperature transmit-      Why should it be secure? Can it be           book will have more lasting value as ref-
ters, safety PLCs, input and output           secure and open? Who should work on          erences. So, even though this book is a
interface modules, valve controllers,         security? How is the cost justified?         must read, it is not a must buy at $54
valves, and many more. It contains            Teumim contrasts IT security issues,         (ISA Member price). It is a great book to
generic failure rate data based on indus-     managed corporately by a CIO and a           borrow.
try database compilations and field fail-     cybersecurity manager, with security for         It is available online at:
ure data, generic failure mode informa-       manufacturing control systems, managed       • ISA online store, www.isa.org/books
tion derived from field failure data and      by a plant personnel like the automation     • Amazon.com

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Safetydivnewslettersummer05

  • 1. ISA Division Newsletter Safety Summer 2005 Brian Smith, Editor Division Director’s Message By Edward M. Marszal, PE, CFSE Dear ISA Safety Division Member, I am very flattered to have been nominated and approved as Director of the Safety Division of ISA. I am very excited about this opportunity and have big plans to expand the membership of the Division by providing Member benefits that will make the Division a “must have” resource for anyone who is involved with engineering instrumentation containing safety aspects. Some of the plans involve expanding the scope of the Division to cover all facets of instrumentation design that have a safety critical impact. This might include such tasks as alarm system design, alarm rationalization, and security considerations for safety instrumented systems (SIS). I firmly believe that in order to make our Division a success we need to provide benefits that cannot be obtained in any other place. We have had a great start under Paul Gruhn, when we established a Division Symposium that has become a must-attend event for safety practitioners, and a Web site (www.isa.org/divatsafety) that contains loads of information that is not available anywhere else. We hope to renew these events starting in Spring 2006. I’d like to continue this path by continuing to expand the value and size of safety-focused conferences and adding more to the Web site sections that are only viewable by Division Members. I’d like to see the Web site expand from providing the papers of past safety conferences (which is an excellent start) to providing electronic tools and data for performing safety lifecycle tasks. This could include IN THIS ISSUE: tutorial presentations in PowerPoint, MPEG, or Flash format, spreadsheet tools for performing SIS related calculations, and submittals of actual proven-in-use field data from end users for Director’s Message 1 various types of equipment. These tools, along with the ability to share ideas and debate tech- niques, both electronically and during conferences, will make Membership in the Division an Past Director’s Message 2 indispensable tool. Safety Instrumented Burner I am also very pleased to announce the 2005 slate of officers and sub-committee chairmen, Management Systems — along with a new line-up of subcommittees. Ready or Not Here They Come! 3 STAFF SUPPORT: Rodney Jones, ISA, (919) 990-9418, rjones@isa.org Application Software VOLUNTEER STAFF: Position Name Company Fault Analysis 4 Director Ed Marszal Kenexis Director-Elect Bud Adler AE Solutions API Standards and Program/Member Chair Carl Sossman (Acting) WSMS Recommended Practices Webmaster/Newsletter Brian Smith Nova Chemicals for Offshore Facilities 6 Alarm Management for SUBCOMMITTEES: Burner Management Systems Safety Alarms 6 Chair Mike Scott AE Solutions Chair-Elect Kevin Maki Book Reviews 7 Control Systems Security Chair David Teumim Consultant Fire and Gas Protection/Detection Chair Charles Fialkowski Siemens continued on page 2
  • 2. Safety Division Newsletter • Summer 2005 Page 2 SUBCOMMITTEES: (continued) Nuclear Safety Chair Troy Martel Past Director’s Message Offshore Safety Paul Gruhn, PE, CFSE Chair David Haysley Albert-Garaudy Associates Safety Division Past Director Chair-Elect C.R.Ragu ONGC I’m pleased to inform Safety Instrumented Systems (Safety PES) you that the Safety Chair Andrew Dennant Emerson Division won three awards in 2003: Safety Field Equipment • Outstanding Divi- Chair Bill Goble exida.com sion — Honorable Alarm Management Mention Chair Chris Wilson TiPS • Most Improved Division For anyone who is considering risk-based inspection consulting. In his • Division Communications Award becoming active in the Division, it is a current position, he has experience in SIS (tied with the Analysis Division) very satisfying and rewarding experi- implementation and process safety man- We were the ONLY Division to win ence. If you see a sub-committee that agement projects for a variety of process three awards! A total of three other does not have a chair-elect and would plants in diverse world-wide locations. Divisions won two awards each. We’ve like to participate, please let me know. Marszal received a B.S.Ch.E. from Ohio accomplished a lot in just two years and Also, we are looking to give Carl State University in 1992 with emphasis have much to be proud of! It wouldn’t Sossman, who has been working tire- on control systems and artificial intelli- have been possible without the work of lessly for the Division, a break from has gence. After receiving his degree he all of our board members. I am especially seemingly endless responsibility for pro- joined UOP, a licensor of process units to grateful to Brian Smith (our Newsletter gram direction with a fresh recruit. I the petroleum and petrochemical indus- Editor/Web Master) and Carl Sossman have some ideas, but if you would like tries, where he performed field verifica- (our 2003 Program Chair). The fruits of to throw your hat in the ring for this tion of control and safety instrumented their efforts are the most visible and high-profile position, please let me systems at customer sites, and designed require the most work. know. and managed development of custom I have completed my two-year term as I am looking forward to a great year control and SIS projects. After leaving Division Director. Erwin Icayan will now with the Division getting back on track UOP he worked with ERM-Risk, a risk take over as Director. Ed Marszal will be in terms of growth and programming. management consulting firm specializing the next Director-Elect. I can’t think of For those of you who don’t know me, in risk analysis and process safety man- two more qualified and capable leaders. I’ve included some bio information agement. In this position he performed A number of the subcommittees are below. Please feel free to call or write to and managed risk assessment projects changing faces as well. Butch Taggart discuss any questions or comments you that included quantitative analysis. (Offshore Safety) will be passing over his have about the Division, or safety Recommendations from these projects chair to Don Ogwude. Don is a consult- instrumented systems in general. were used to ensure regulatory compli- ant who spent many years with Chevron ance, justify risk reduction expenditures in California and is a member of the ISA Edward M. Marszal, PE, CFSE and optimize insurance coverage. He SP84 committee. Mike Scott and Kevin President, Kenexis Consulting teaches many of the Kenexis courses on Maki will be swapping their roles as Corporation process safety management and safety chair and assistant in Burner Management Phone: (614) 451-7031 ext. 1 instrumented system design and analysis. Systems. Simon Pate will be passing his Fax: (614) 451-2643 He also regularly lectures on loss preven- chair position in Fire & Gas Systems over Mobile: (614) 226-4263 tion topics at Ohio State University. to Robert Seitz. Robert is a PE in Alaska E-mail: edward.marszal@kenexis.com Marszal peer reviews papers for ISA who specializes in such systems and serves http://www.kenexis.com Technical Conferences and ISA on several standards committees. Transactions, and is the author of the Palaniappan Kannan will serve as our BIO: Mr. Marszal has over twelve years award winning ISA book Safety Integrity 2004 Spring Program Chair. Kalpen of experience in safety instrumented sys- Level Selection. He is active in ISA at the Vachharajani will serve as our 2004 Fall tems design and risk analysis. He is local and national levels, holding several Program Chair. President of Kenexis Consulting positions with the ISA Columbus Section, Division board members have discussed Corporation and responsible for engi- of which he is currently Vice-President, the idea of having Security receive a neered safeguards design basis consulting and as a member of several safety related much higher profile within the Division including: safety instrumented system standards committees, including SP84, (than it’s current subcommittee status). implementation projects, process hazards SP91, and SP18. He is a registered pro- We discussed this with the Chair of our analysis, quantitative risk analysis, alarm fessional engineer in Ohio and Illinois Security Subcommittee and certain mem- management and rationalization, pres- and also a TÜV certified functional safe- continued on page 3 sure relief valve and system surveys, and ty expert.
  • 3. Safety Division Newsletter • Summer 2005 Page 3 Safety Instrumented Burner Management Systems Ready or Not Here They Come! Michael D. Scott, P.E., Safety Division BMS Chairman VP – Process Safety, AE Solutions, P.O. Box 26566, Greenville, SC 29616 The concept of a Safety Instrumented • EN 50156-1 – A German standard • FM Representative Burner Management System (SI-BMS) is covering electrical equipment for • NFPA 85/86 Representative here to stay. If you are unsure of this furnaces that is scheduled for • ISA SP84 BMS Sub-Committee statement one should consider that six revision in 2004. This document Member different codes/standards currently exist invokes SIS requirements for a • Process Industry End Users and/or are being revised to invoke the BMS. Safety Lifecycle with respect to Burner • API 556 – Document governs Management Systems. This includes the design of BMS’s in the petroleum following: industry. Is being revised to invoke • The Black Liquor Recovery Boiler SIS requirements on BMS’s. Advisory Committee (BLRBAC) has developed several guideline To promote the SI-BMS concept, ISA documents regarding design and has developed a Web seminar and is in operation of Recovery Boilers in the process of introducing a one-day the Pulp and Paper Industry. These course on this topic. The schedule for the documents invoke SIS requirements next BMS-related training is as follows: on the Recovery Boiler BMS. • Is a Burner Management System a • FM 7605 – Factory Mutual Safety Instrumented System? Web requires that any PLC listed for use seminar 14 July 2005 & 16 in combustion safeguard service November 2005 meet the SIS requirements con- • Safety Instrumented — Burner tained in IEC 61508. At this writ- Management Systems: A How To ing we are aware of only one ven- Primer One-day seminar (Dates to dor who has a product submitted be announced in the near future) to FM for approval with respect to SI-BMS. If the above subject is of interest to Check out this • SP84 – The ISA SP84 committee you, or if you have other intriguing informative book has formed a BMS sub-committee questions regarding BMS designs, the to develop a document that clari- Safety Division provides an excellent from ISA. fies how SIS concepts apply to a forum to search for answers. This can Go to www.isa.org/ BMS. Examples being included in be accomplished in three ways: safetyreliability for more the document for each code or 1) Join the Safety Bulletin Board and standard are: post your BMS questions for the information on this and other • NFPA 85 – Single burner boiler Division members to answer. safety-related books from ISA. • NFPA 86 – Thermal oxidizer 2) Plan on attending ISA EXPO 2005 Read a review of this book • API 556 – Process heater with in Chicago. A BMS paper session multiple burners and/or panel session is planned to on page 7. • API 14C – Reboiler address this subject. Contact Mike • API 14C – Heater Treater Scott if you wish to present papers The goal of the SP84 committee and/or participate in a panel session is for industrial users to properly on BMS designs. Past Director’s Message follow the safety lifecycle to define 3) The ISA EXPO 2005 panel session continued from page 2 the risk associated with every BMS will provide a forum for the audi- to determine if it is a SIS. ence to ask questions of industry bers of the SP99 security standard com- • NFPA 86 Committee is planning to experts on the design and applica- mittee. ISA has already had at least two update this standard to reflect their tion of BMS’s. The goal of this Security Conferences. It would make agreement that an industrial BMS panel session is to review NFPA sense for both groups to join forces and is a SIS and that a safety PLC requirements for BMS’s and com- take advantage of the synergy. Perhaps should be used. A linking para- pare/contrast these issues with the we may change our name to the Safety & graph will be added that refers to requirements of SIS standards (i.e. Security Division. Stay tuned for where ANSI/ISA-84.00.01-2004 as ANSI/ISA-84). Erwin may lead us in this area. acceptable methodology. • Proposed Panel Session Members It’s been a pleasure serving with you.
  • 4. Safety Division Newsletter • Summer 2005 Page 4 Application Software Fault Analysis Palaniappan R. Kannan SISRA Consultants, Singapore 650319, Rmp66@singnet.com.sg Abstract are the ones that can be used effectively • Improper handling of data types A Programmable Electronic System and when they should be used in the • Truncation and rounding off errors (PES) consists of both hardware and process of software development. This • Improper handling of abnormal software. Hardware failures are pre- requires knowledge about the software conditions dictable whereas software faults and faults that occur in the first place, which • Calculation overflow failures are not. These software compo- needs to be categorized in order to nents are what make PESs more com- understand the problem areas. Variable Initialization: The initial val- plex. The only way to address software The major categories of application ues assigned to variables at the start and related failures in PESs is through imple- software faults are: re-start of program execution need to be mentation of proper development • Calculation error free for the proper execution of process, programming methods and rig- • Variable Initialization the programs and resulting outputs. In orous testing. This article will review • Timing Synchronization case of hardware or processor redun- various types of faults that can occur in • Interface dancies, the variable values should application software development. • Change Impact transfer correctly for proper continua- • Omission/Commission tion of their succeeding runs. Counters Introduction • Configuration Management and timers also need to be considered. Application software is one of the • Data Typical problems found in variable ini- components that contributes to the • Requirement Specification tialisation are: unavailability of a PES. Software failures • Logic • Lack of, or incorrect, initial values are one type of systematic failures that when programs start or restart reside inside the system as built in faults. Calculation: Calculation errors can be • Initial or present value storing and In order to avoid software based failures due to programming the algorithm/for- transfer problems for succeeding of a system, it is important to identify mula incorrectly or computational errors. runs and hardware transfers and rectify all the software faults during Types of registers, their addressing meth- the various phases of its development. ods, and the way the processor handles Timing Synchronization: This factor Many software faults are not self-reveal- the floating-point values are different for comes into play when there is real time ing. Also, unlike hardware failure rates, different systems. Proper understanding execution of software processes and software failure rates are not predictable of these points is essential. Typical prob- when different processes executed in dif- and cannot be accurately quantified. lems found in calculation faults are: ferent domains need to interact. Failure rates cannot be used effectively • Incorrect coding of constants Depending on the points of interaction to determine safety integrity levels. • Improper handling of boundary this can affect data acquisition, code There are many reasons for software- conditions execution, system functioning, and/or related failures. These range from poor development processes, application Software complexity, interaction between mod- Software Validation ules, poor personnel competence, vari- Requirement Testing Specification ability, and use of off-the-shelf software. Software Development Process The first step in avoiding software Software faults is to follow a good development Architecture Software and System Integration process. The process should handle the Testing Design complexity associated in the development of software. Various standards recom- mend the classic “V-model” (see Figure 1), which emphasizes modular develop- Software Module Software Module ment and testing each phase. Test plans Testing Design and methods need to be established. Software Faults There are numerous methods for Figure 1: The V-Model software fault prevention and detection. of Software Development However, it’s necessary to know which Software Coding and Testing continued on page 5
  • 5. Safety Division Newsletter • Summer 2005 Page 5 continued from page 4 configuration management procedures Logic: Logic faults have their roots in system outputs. Typical problems found should be adopted throughout the soft- requirements, design and/or code. Logic in timing synchronization are: ware lifecycle. Three areas that require problems do not relate to phases, but • Interacting processes going out of configuration management is required rather to the whole development process. synchronization are documentation, hardware, and soft- Competent personnel and their ability to • Inaccurate real time clock ware. Software versioning tools are now understand the requirements are key. • Non-occurrence of event due to available as part of application develop- Typical logic related problems are: timer failure ment. Configuration management also • Faults due to incomplete or incor- helps to set responsibilities and account- rect logic Interface: In order to perform its ability and should be part of software • Faults due to interaction between functions and provide useful output the development management. Typical various modules system software needs to interface with problems in configuration management • Improper functioning during other system devices and software. are: abnormal conditions and states These can be inputs devices, outputs • Selection of incompatible hardware • Coding errors devices, or other systems performing and software other functions. The requirement speci- • Failure to upgrade other systems to Conclusion software changes This article reviewed various types of fication should describe all interface • Use of incorrect master program faults that can occur in application soft- needs. All interfaces should be traceable for software revisions ware development. Adopting a good to the requirement specification. Typical development process is of paramount problems found in interfaces are: Data: Faults can occur due to data importance. It is important to identify • I/O interface errors types, units, range values, and acceptable probable fault categories and the neces- • Calling of incorrect functions and change magnitude/frequency. Hardware sary techniques that need to be used to sub-routine manuals should exist and should provide avoid them. The identified fault cate- • Mistakes in passing of parameters details about the limitations in data codi- gories and detection/prevention tech- fication. Programs should contain diag- niques need to be assigned to various Change Impact: Software development nostic code to handle data faults, such as phases of the development process. Once contains many feedback paths. Revisiting data validation techniques. For example, this is done, resources can be identified earlier phases and making changes are all input data can have a valid range and test cases can be prepared. common. After all, software requirements specified, and if a value goes out of range However, it is difficult to identify are based on overall system requirements a diagnostic alarm can be triggered. one’s own fault. This also applies to the and changes in software requirements can Another way of avoiding data faults is to software development team. Therefore, also occur as the design progresses. Every use typed data tables. Typical data relat- review by different competent persons time a change is incorporated, the overall ed problems are: not belonging to the team can greatly impact of that change should be studied • System failure due to invalid input help in fault finding. Assessment and thoroughly. Typical problems due to data assurance can accomplish this. change impact are: • Problems in database data retrieval Every software application is unique, • Inability to properly execute logic and so are its faults and failures. Iden- and sequential function Requirements: The starting point of tification of faults requires feedback • Incompatibility of existing systems software development is the requirement from existing applications. Therefore, with changed device specifications. This is critical for the fault related data collection from differ- • Loss of existing function completeness and correctness of the final ent applications can be of great value in • Change not verified and validated product. Care should be taken to devel- understanding the types of problems in op a correct requirement specification specific application domains and devel- Omission/Commission: Anything which should deal with performance oping prevention/detection techniques. produced by human beings is subjected to omission and/or commission errors. requirements, functional requirements and interface requirements. Semi-formal References Software is no exception. These errors methods such as function block dia- 1. Functional safety of electrical/elec- can result in missing required system grams, flow charts, truth tables, etc., can tronic/programmable electronic safety- functions and/or additional system func- be used in specifying various functions. related systems, IEC 61508, 2000, tions not required by system. System Verification and validation are key steps International Electrotechnical functional documents, which are to ensure that the software produced Commission, Geneva, Switzerland. required as part of the development complies with the requirements. Typical 2. Wallace, Dolores R., Laura Ippolito, process, can also have omission and problems caused by requirement specifi- and Barabara Cuthill, “Reference commission faults. Typical problems cations are: Information for the Software Verification due to omission and/or commission are: • Unspecified exceptional conditions and Validation Process,” NIST SP 500- • Missing (or) improper documentation and states 234, National Institute of Standards and • Missing specification requirements • Missing functions in the specification Technology, MD 20899, April 1996. • Missing functions Configuration management: Good • Unspecified testing requirements continued on page 6
  • 6. Safety Division Newsletter • Summer 2005 Page 6 continued from page 5 API Standards and Recommended Practices Author Bio Palaniappan Kannan has 18 years of for Offshore Facilities instrumentation, process, control and safety system experience. He has To understand the needs of the • API RP 14G – “Recommended worked in various phases of oil and gas upstream segment facilities for the Practices For Fire Prevention and and petrochemical projects in operation petroleum industry, it is necessary to be Control on Open Type Offshore and maintenance, engineering, consul- familiar with the basic standards that Production Platforms” tancy, and system integration. are used. During the coming year, it is • API RP 14J – “Recommended Palaniappan has a Bachelors degree in the goal of the ISA Safety Division Practices For Design and Hazards instrumentation and is a Certified (Offshore Sub-Committee) to develop Analysis for Offshore Production Functional Safety Expert (CFSE). CFSE is and publish papers on some of the Facilities” an accreditation by TÜV certifying com- applicable API standards and recom- As Chairman of this subcommittee, I petency to implement Safety Instrument mended practices that deal with safety am requesting input on these documents, Systems (SIS) in line with international issues in the design, fabrication, installa- or any other documents that would be standards such as IEC 61508 and IEC tion, and operation of this segment of applicable. Details on any experience 61511. Palaniappan has a Masters degree the petroleum industry. It is intended with combining the requirements of these in Business Administration (MBA) and is that these papers will cover general safe- API documents and the ISA/IEC SIS stan- a certified Project Management ty issues and, to the extent possible, dards would be greatly appreciated. If Professional (PMP-PMI). focus on BPCS, Fire and Gas Detections you have papers, or want to develop a Palaniappan is actively involved in Systems, and SIS. Co-ordination of these paper, please contact us. professional bodies like ISA and IEEE. documents with the current ISA Also if you have any recommendations He has published articles and developed (ANSI/ISA-SP84.00.01) & IEC (IEC- on other activities that our subcommittee software tools in the SIS area. He is a 61511) standards will also be addressed. should pursue, we would like to hear committee member of ISA SP84- Preliminary Listing of Documents: them. Programmable Electronic System (PES) • API RP 75 – “Development of for Use in Safety Applications and ISA Safety and Environmental Contact: SP99 – Manufacturing and Control Management Program for Outer David Haysley System Security standard committees. Continental Shelf Operations and Albert-Garaudy and Associates, Inc. Throughout his career Palaniappan Facilities” 3500 N. Causeway Blvd. has been involved in HAZOP studies, • API RP 14C – “Recommended Metairie, LA 70005 developed SIS specifications, engineered Practice for Analysis, Design, (504) 846-6466 SIS systems, performed SIL verification Installation and Testing of Basic Cell: (504) 231-5262 calculations, and developed SIS func- Surface Safety Systems for dhaysley@aga-engineers.com tional testing procedures. Offshore Production Facilities” Alarm Management for Safety Alarms At ISA EXPO 2004 last year, I had similar to a HazOp study. Some support imize the possibility of a mistake when the opportunity to sit down and discuss a more simplistic view, a “lightweight” removing or changing alarms, consider a growing concern that current trends in version of alarm management that does the mass of alarms that were added “alarm management” ignored the safety not involve the paperwork, personnel, without any formal review. ramifications of changing the alarm sys- resource overhead of a “HazOp-style” Alarm management projects are tem. The conversations centered on the alarm management project. intended to remove the smoke from oper- loss of safety related alarms due to People who support a more compre- ators’ eyes. How much of that smoke was incomplete or arbitrary reviews prior to hensive approach to alarm management arbitrarily implemented? Perhaps if we the removal or modification of alarm almost always focus on the process of embraced a HazOp-style process of alarm system settings. Emphatic points were removing alarms. Don’t doubt that a system design and of controlling changes, made in support of a safety-centric holistic review and redesign of an alarm we can prevent the need for massive review process, or at least for the inclu- system can be a painful proposition. alarm redesign projects in the future. sion of HazOp information during the There is no magic button that can review process. reverse what has already become a Chris Wilson Many involved in defining what alarm problem, but there is a way to prevent Marketing Manager management is embrace a safety oriented the problem in the future. TiPS, Inc. viewpoint and feel that it aligns well with Alarm management exists because (512) 863-3653 x 520 their already established opinion that the alarms have gone out of control. Some chris@tipsweb.com process of alarm management should be level of due diligence is required to min-
  • 7. Safety Division Newsletter • Summer 2005 Page 7 Book Reviews FMEDA data and many product specific and control manager. The shift of control entries based on specific FMEDA data systems from proprietary to commercial- from TÜV, FM, exida and others. off-the-shelf hardware and software and The handbook can be purchased network connectivity have created new through the following three sales vulnerabilities in industrial networks. But channels: cybersecurity alone is not enough. A • exida.com online store complete security program also includes • ISA online store, www.isa.org/books personnel security, and physical security. • Amazon.com Cybersecurity consists of protecting the availability, integrity, and confiden- tiality of the systems and data. This Safety Equipment Reliability requires understanding the threats to the systems and the vulnerabilities of the Handbook systems. Threats like the Slammer worm Published by exida.com and buffer overflows are explained. ISBN: 0-9727234-0-4 Some of the highlights of this book are the examples of real attacks on control Are you performing Safety Instrumented systems and the consequences. Function verification calculations? Countermeasures can be designed to Regardless of what method you are using protect against the threats. Usually a – Simplified Equations, Reliability Block system for identification, authentication, Diagrams, Fault Tree Analysis, Markov and authorization is one of the most Modeling, or a commercially available important layers of defense. tool – you need failure rate and failure The remainder of the book covers the mode data. The exida Safety Equipment Industrial Network Security steps, at a very general level, to execute Reliability Handbook contains the infor- By David Teumim an industrial network security program. mation you are looking for. Published by ISA The first step is planning and design for The exida Safety Equipment ISBN: 1-55617-874-3 security, such as separation of networks. Reliability Handbook was officially An understanding of the technology, like released in March 2003. The handbook The ABCs of Network Security encryption and firewalls is important. was created to solve one of the major Reviewed by Nick Sands To make an effective security system problems when implementing Safety One of the hottest topics in the con- requires writing clear policies for the Instrumented Function verification cal- trol industry is security for process con- application of technology, trained and culations, i.e. getting failure rate and trol systems and networks. Finally ISA aware people, and periodic audits and failure mode data. The handbook was has a book on the subject: Industrial other methods to provide assurance of created to supply that information in a Network Security by David Teumim. the effectiveness of the security pro- format specific to safety integrity verifi- Teumim is a certified information system gram. Some example approaches to cation and to allow for easy comparison security professional (CISSP) and a industrial network security programs between equipment items or designs on workgroup leader for SP99, the commit- from Dupont and Proctor & Gamble failure rates, failure mode distributions, tee working on manufacturing and con- form the last chapter. and diagnostic detection capability. trol system security. The book is very Every company in the control commu- (This is the primary difference between basic – an introduction to an introduc- nity will have people that can benefit the exida handbook and other more tion on the subject. But with such a new from reading this book, people that need generic reliability data sources, such as area, this elementary book is a good a basic understanding of information OREDA – Offshore Reliability Data, beginning to the body of knowledge. security for manufacturing and control AIChE, IEEE, and others.) The first chapters are an introduction systems. Teumim just introduces the sub- It contains data on a wide variety of and background, answering many ques- ject though, with little detailed informa- safety-related equipment, such as pres- tions. What is an industrial network? tion. Future books or revisions of this sure transmitters, temperature transmit- Why should it be secure? Can it be book will have more lasting value as ref- ters, safety PLCs, input and output secure and open? Who should work on erences. So, even though this book is a interface modules, valve controllers, security? How is the cost justified? must read, it is not a must buy at $54 valves, and many more. It contains Teumim contrasts IT security issues, (ISA Member price). It is a great book to generic failure rate data based on indus- managed corporately by a CIO and a borrow. try database compilations and field fail- cybersecurity manager, with security for It is available online at: ure data, generic failure mode informa- manufacturing control systems, managed • ISA online store, www.isa.org/books tion derived from field failure data and by a plant personnel like the automation • Amazon.com