A Novice’s Overview Of Safety Lifecycle Manager (SLM )
A Novice’s Overview of SafetyLifecycle Manager (SLM )www.Mangansoftware.comwww.Mangansoftware.com
Table of Contents1Introduction2The Safety Lifecycle3Safety Lifecycle Manager (SLM) in a Few Words4How SLM is Used5SLM for the Process Safety Management Organization678SLM for Engineering OrganizationsSLM for OperationsSLM for Maintenance9SLM for Management1011SLM AdministrationConclusion030304050707080910101102
1 IntroductionThe Safety Lifecycle Manager software suite(SLM ) is comprised of 16 software modulesthat encompass the entire IEC 61511/ISA84 Safety Lifecycle. Developed and offered byMangan Software Solutions (MSS), SLM is theforemost software application that provides anenterprise, manufacturing site, or engineeringproject with the capabilities to execute,manage and fully document Process Safetyand the Safety Lifecycle in one integrateddatabase solution. The application providesbasic and comprehensive Safety Lifecyclefunctions as well as an extensive set ofoptional auxiliary functionalities.No matter what level of functionality a userrequires, SLM offers exceptional value inreducing costs and leveraging benefits for theSafety Lifecycle. While the Safety Lifecyclecan be daunting if you are new to the process,or if you are managing what appears to be adifficult and expensive undertaking, SLM isdesigned as an intuitive, robust, andintegrated suite of modules using workprocesses that provide a rapid path to successfor every facet of Process Safety and theSafety Lifecycle.This White Paper is intended to provide anoverview of SLM for novices in the SafetyLifecycle or for managerial personnel who onlyneed to understand the importance of theSafety Lifecycle and be aware of what reallyneeds to be done for each phase of the SafetyLifecycle.MSS offers a series of White Papers and othersupport material for those who need a moredetailed understanding of the Safety Lifecycleand the usage and capabilities of SLM.2 The SafetyLifecycleThe Safety Lifecycle grew out of severalcatastrophic events that happened across anumber of industries. There was a realizationthat organizations around the world were nothandling process hazards and their mitigationsvery well, and as a result calamitous eventsinvolving loss of life and massive economicand environmental impacts were occurring.Various industry-standards organizationsstarted looking at what could be done, and anumber of standards were developed. Amongthem are ISA 84, IEC 61508 and IEC 61511.These standards are extensive and complex,but they all come down to a few principals:Process hazards need to be identified ina formalized and consistent way.03
The severity and likelihood of processhazards need to be categorized in aformalized and consistent way.When the risk posed by a processhazard is deemed to be unacceptablyhigh, mitigations must be identified thatreduce the risk to acceptable levels.These may be design requirements forequipment (e.g., designpressure/temperature); instrumentedfunctions,such as alarms, controls,interlocks, and safety shutdowns; orphysical protections, such asoverpressure protection, dikes andbarriers, and mechanical interlocks.Mitigations identified must have specificfunctional requirements defined, whichinclude the expectations that themitigations will actually function whenthey are required.Mitigations that are installed must betested and maintained to assure that theexpectations for functioning whenneeded are met.Personnel that operate and maintain theprocesses must be properly trained onthe mitigations that have been installed,including operation and maintenancerequirements associated with them.Performance of mitigations must bemonitored and where performance is notmeeting expectations, corrective actionsmust be performed.All modifications must be managedthrough a formalized management ofchange process.Records must be kept of theperformance and design expectations formitigations, testing, demand, fault/failureand periods where the mitigations aredisabled, non-functional or bypassed.Compliance with the above items is not asimple task. It can involve crossing traditionalorganization boundaries, creatingdocumentation that is hard to maintain andshare, and adding operating and maintenanceresponsibilities on an already stretched staff.The SLM application is designed to eliminatemost of this burden and allow Safety LifecycleManagement to be efficiently and effectivelyintegrated into existing organizations.3 SLM in a FewWordsSLM is based upon a set of ten modules thatcover the entire Safety Lifecycle. Thesefunctional modules may be licensed togetheror separately, depending upon a particularusers’ needs. In conjunction with the functionalmodules, there are six platform modules thatare common to all the SLM safety lifecyclemodules and are provided with each SLMinstallation. Collectively, these six modules areidentified as the SLM Atlas PlatformModules. The safety lifecycle functionality ofthese modules is comprehensive andextensive, so only the main functions andfeatures are described in this White Paper.MSS has published a number of additionalWhite Papers and other supporting material toprovide more detailed descriptions of SLMmodules’ functions.04
The ten SLM modules for Process Safety and theSafety Lifecycle are:HAZOP Module - Provides the all new“HAZOP Quick Workflow ” to perform anddocument results of Hazard and Operability(HAZOP) and other Process Hazard Analysis(PHA) studies. Users can import data fromother applications or perform HAZOPs andother PHAs within SLM. This modulereplaces the former PHA/HAZOP Module.LOPA Module - Links to selected HAZOPand other PHA cases and documents Layerof Protection Analysis (LOPA) studies andidentification of Independent ProtectionLayers (IPL). IPLs identified by LOPAs maybe directly linked to actual site assets that areused to implement the functions.Bowtie / Barrier Assurance Module Incorporates existing hazard analysis data tofacilitate risk analysis and risk assessmentson mitigation and prevention barriers.Instrumented Systems Module Documents instrumented functions anddevices used to implement IPLs.Non-Instrumented Systems Module Documents non-instrument assets used toimplement IPLs.Relief Systems Modules - Documents reliefsystems and devices used to implementoverpressure prevention IPLs.Operate and Maintain (O&M) Module Allows users to enter events for a widenumber of types of IPL functions and theirdevices. Reports on Safety Lifecycleperformance metrics such as Test History,Demands, Failures, Bypasses, and ServiceStatus. The O&M Module presentsperformance data based upon enteredevents.Functional Safety Assessment (FSA)Module - Allows users to conduct anddocument Functional Safety Assessmentsrequired for Safety Instrumented Systems.Action Item Tracker - Provides a means forusers to define and track action items withinSLM. Action items created in other modules,such as the FSA and MOC modules, arelinked to this module.Management of Change (MOC) Module Provides a means for users to generate,approve and track MOCs within SLM. Themodule provides checklists for MOCgeneration and hazard assessments. Usersmay create action items within the MOCModule, which are then linked to the ActionItem Tracker Module.The six SLM Atlas Platform Modules are:Home Dashboard Module - Users can tailortheir dashboard from over 150 reports, dataviews, and KPIs throughout SLM using dragand drop creation methods. Users canaccess recent items, quick links, bookmarks,and available modules, plus globally searchthe SLM database.Global Module - Allows users to defineoverall enterprise and site organization andSafety Lifecycle policies.Personnel Module - Allows administrators todocument individual roles and qualificationsand to define functions such as eventapproval scope for individual users.05
Document Management System Module Every object in SLM can have associateddocuments. Document management toolsprovide searches of PDF documents,configurable mapping and ranking ofdocuments, remote linking of documents viaURLs, and tracking of document versions andexternal revisions.System Configuration Module - Allowsadministrators to manage SLM users and thedata which they can view, change, create ordelete and manage general system widefunctions.Import Adapter - Allows users to define andstore import templates for standard CSV dataimport files. Adapters are also available forcommon data import formats, as well as adata mapping tool to allow users to map datafields to object fields from an import file.4 How SLM is UsedSLM is a web-based application. Theapplication and its database are offered as‘software as a service’ (SaaS) or installed on ahost server at user organization’s site orenterprise location. SLM SaaS may be acommercial server or virtual server, availablethrough MSS or a third party. An importantfactor is that the SLM application can beavailable to authorized users without requiringany local installations. SLM contains cybersecurity functions that meet typical corporaterequirements.SLM is intended to be used by multipleorganizations within an enterprise or facility. WhenSLM is set up, the organization is defined in termsof the enterprise, sites within the enterprise, andunits within sites. Data is generally recorded at theunit level, which can include alarms, alarm groups,Basic Process Control Systems (BPCS), F&GF ,interlocks, Safety Instrumented Functions (SIF),Safety Instrumented Systems (SIS), cause andeffect (C&E) matrices, and high integrity protectionsystem (HIPS) objects. MSS can customize theentire enterprise structure to meet a userorganization’s requirements.Many portions of SLM are customizable. Thisincludes setting up user roles, defining the contentsof dropdown and pull-down lists, checklists, andother readily modified data. SLM may also befurther customized to match a user’s specificrequirements. This level of customization requiresmodification of the SLM code and is available as aservice from MSS. The White Paper Getting Readyto Use SLM describes the things that need to beconsidered when first setting up an SLM installation.SLM is licensed by the module or in sets ofmodules, but modules not selected at the initialinstallation can be added at later dates. Thedecision to exclude some modules will not affect thefunctionality of other modules.06
5 SLM for theProcess SafetyManagementOrganizationThe primary SLM modules that a processsafety management organization will use arethe HAZOP and LOPA Modules. Thesemodules may be used in a variety of waysdepending on the organization’s requirements,including:Importing of existing HAZOP and LOPAdata into SLM from other applications,spreadsheets, etc.Performing HAZOPs and LOPAs directlyin SLM. Once existing data has beenimported, subsequent HAZOPs andLOPAs can be performed within SLM.Managing multiple parallel HAZOPs andLOPAs such as those originating fromcapital projects and Management ofChange hazard assessments associatedwith site executed work.SLM uses a Dynamic Risk Matrix to allowprocess safety management organizations toeasily understand where in the enterprise thatrisk is concentrated. When used with theO&M Module, the current status of riskincurred by the performance and testingstatuses of the protective functionsimplemented in each site and unit is recordedand viewable.6 SLM forEngineeringOrganizationsThe primary modules that an engineeringorganization will use are the InstrumentedSystems, Non-Instrumented Systems, andRelief Systems Modules. Depending upon aparticular organization’s needs, theengineering organization may also use theSLM Functional Safety Assessment Module.The first three modules are used to capture theexistence of plant assets that are used toimplement Safety Functions identified byPHAs, including HAZOPs and LOPAs.Examples of plant assets for Safety Functionsinclude:Safety Instrumented Systems (SIS)Safety Instrumented Functions (SIF)Alarms associated with LOPA IPLsBPCS functions associated with LOPAIPLsNon-SIF interlocks, trips, etc. associatedwith LOPA IPLsNon-Instrumented IPLs such asmechanical stops, dikes, etc.Relief Systems and relief devices07
Each function may then have Input and Output(I/O) assets associated with the function.These are organized to allow users to specifyvoting groups such as 2oo3, 2oo2, etc. SLMalso uses the voting group definitions tocompute the function’s Probability of Failure onDemand (PFD) using a variety of failure ratesources. Basic functional requirements for I/Oassets such as accuracy, response time, userdefined failure rates, etc., may be captured inSLM. Detailed device data is specified underdevices in the O&M Module.SLM allows the user to link specific PHA,HAZOP, and LOPA scenarios with the plantassets identified in the engineering modules.This allows the user to easily access theprocess hazards that require the function to bein place and identify all of the plant assetsassociated with a specific scenario.SLM also allows the user to easily specifySafety Requirements Specifications (SRS) forSISes. Each SIS object contains all the datafields required to develop an SRS thatcomplies with IEC 61511 and ISA-84requirements.Once a set of functions and their I/O assetsare defined, SLM allows authorized users toclone all or part of data sets to create a newobject. Similar SISes, SIFs and I/O assets canbe copied and then edited for the specificapplication. This minimizes the work requiredto create new SISes, SRSs, SIFs and IPLs andenforces consistency in format and content.Engineering groups also will use the SLMO&M Module to monitor and report on theperformance of SISes, SIFs and other IPLs.The O&M Module provides reports anddisplays that identify the following:Testing status, upcoming or overduetestingDemand, bypass, and fault/failurestatistics for all functions and devicesIn-Service failure rate data for devices.This data is available by device ID,device type and device generic models.The In-Service failure rate data is alsoavailable to the Instrumented SystemsModule to calculate SIF or other IPL InService PFD values.During initial design and subsequentoperation and/or modifications, the ISA andIEC standards require performance of FSAs.The SLM FSA Module allows users to createFSAs for SISes at each of the stages identifiedby the standards. The FSAs use a standardizedset of checklists to assure completeness andconsistency across an enterprise.7 SLM forOperationsOperations groups may use SLM to betterunderstand the protective functions for whichthey are responsible and to record operationrelated events in the O&M Module. They alsouse the O&M Module to understand theperformance of the protective functions in theirarea and to record operations related events.08
Operations personnel such as supervisors,process engineers and operators may be allowedto have view only rights to the process safetymodules (HAZOP and LOPA) and engineeringmodules (Instrumented Systems, NonInstrumented Systems, and Relief Systems).This allows operations personnel ready access towhat the protective functions do, why they exist,and what equipment is associated with theprotective functions. For example, an operatormay view the data for a SIF and then be able toaccess the LOPA for that SIF in order tounderstand what a function does, what fielddevices are part of the function, and the hazardsthe function protects against.The O&M Module allows operators and/orsupervisors to directly enter operations relatedevents. These events include:Demands upon SIFs or other IPLs, whatdevices were associated with the event,and whether the function responded to thedemand as expected or not.Faults and failures associated with SIFs orother IPLs and their devices.SIF or other IPL bypasses. This includesrequests for bypass approval includinghazard assessments and supplementaryoperations procedures, the date and timethe bypass was initiated and the date andtime the bypass was removed, and thefunction restored to normal operation.SLM provides operations personnel withperformance data associated with protectivefunctions.Users are informed as testing becomes due or isoverdue and of function performance, such asdemands, failures, and bypass time.The operating company was able to efficientlygather and analyze Tier 3 metrics for each IPLincluding:8 SLM forMaintenanceMaintenance groups use SLM in a manner similarto operations groups. This includes having thesame view level access to engineering and ProcessSafety information for the units and functions withintheir areas of responsibility. The maintenancegroups will also use the O&M Module to monitor,schedule, and record maintenance activity. Thesefunctions include:Monitoring the test status for SIS, SIF andother IPL functions and identifying upcomingor overdue testing.Recording test results for functions and theirdevices.Recording maintenance events that occurbetween testing events.09
Recording replacement of devices, whichmay be an engineering activity dependingupon an organization’s practices.Recording changes in the Service Status ofSISs, SIFs or other IPLs and their devices,which may be an engineering activitydepending upon an organization’spractices.9 SLM forManagementSLM provides tools for management at variouslevels to monitor Process Safety at the unit, site,and enterprise levels. Among the reports and viewsavailable are:Dynamic Risk Matrix views that identifyrelative risk by unit, site and enterprise level.Protective function performance summariesthat identify areas that have overdue testing,high demands or excessive bypassing.Tools that support identification ofqualifications, roles, and responsibilities forindividuals within an organization.10 SLMAdministrationSLM provides tools for overall user and applicationdata management in the System Configuration andGlobal Modules. These include:Management of User IDs and the scope ofview or modification of data. Users may begranted view or modification rights for specificunits, one or more sites or the enterprise.Management of drop down and pull-downlists, checklist items, or other general dataused by the modules.Management of approval policies for eventsincluding identification of approvers by eventtype, site, or unit.Management of enterprise-wide genericmodels and which sites use which genericmodels.0810
11 ConclusionsMangan Software Solutions engineered SLM as asingle platform solution for the complete SafetyLifecycle. SLM is the world's first and only TÜVcertified process safety intelligence platform. It iscomprised of a core set of modules used toconfigure and manage the system across the entireenterprise and a comprehensive set ofinterconnected application modules covering theentire Process Safety and Functional SafetyLifecycle.From HAZOP and LOPA studies, to SIS design,and through operations and maintenance, SLM hasall the tools needed to successfully manageProcess Safety and the Safety Lifecycle. Users cancollect, record, and quickly access current andhistorical data used to manage the performance ofProtective Functions. SLM is an enterprise readysolution that maximizes the effectiveness andminimizes costs for successfully performingProcess Safety and the Safety Lifecycle.Users can configure and manage custom userinterface logos, font styling, units of measure,language translation, usage metrics, APIinterfaces, and data objects. The process andfunctional safety modules are designed andintegrated to be extensible, so data can bestored and managed within a commonframework, but which can be customized to suitany enterprise’s requirements.11
functions,such as alarms, controls, interlocks, and safety shutdowns; or physical protections, such as overpressure protection, dikes and barriers, and mechanical interlocks. Mitigations identified must have specific functional requirements defined, which include the expectations that the mitigations will actually function when they are required.
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