A Practical Approach to Integrate Process Hazard Analysis (PHA) Risk Identification Based on Incidents and Management of Change (MOC)

A given Safety Instrumented Function design must be verified to meet the required SIL level by calculating probability of failure on demand. However, this does require realistic failure rate data for each device. Fortunately, many device manufacturers are getting their products certified per IEC 61508 and many of the certificates now have failure rate data. Other manufacturers supply analysis reports with failure rate data. But how good is this data supplied by the manufacturers? All such data must be checked to make certain it is applicable for the process industries as some data may have been derived based on machine safety or automotive applications.

This paper will show some examples of manufacturer provided failure rate data and a methodology created to validate device type failure rate data for the process industries.