Technical Operations & Maintenance Roles in the Safety Lifecycle (EC51CT)

Length: 1 day
CEU Credits:  .7
Course Hours:  8:00 a.m. - 4:00 p.m.
Certification of Completion: A Certificate of Completion indicating the total number of CEUs earned will be provided upon successful completion of the course.


This course focuses on the specific activities operations and maintenance personnel need to understand and perform to ensure the safety lifecycle as contained in ANSI/ISA S84.00.01-2004 Parts 1-3 (IEC 61511 MOD) is improving the process safety performance at their facility or the facility they are associated with designing / constructing.

IEC 61511 mandates a performance-based safety lifecycle approach to risk management.  Operations and maintenance staff perform a critical role in the safety lifecycle.  In fact, operations and maintenance staff will determine whether or not the actual benefits of safety lifecycle compliance will be achieved or not.  Thus, it is imperative that operations and maintenance staff have a good understanding of the specific actions / tasks they need to perform to ensure compliance with IEC 61511 and, more importantly, to improve the process safety performance at their facility or the facility they are associated with designing / constructing.

You will be able to:

  • Define operations and maintenance requirements associated with the safety lifecycle
  • Recognize what information needs to be included in a "good" test plan
  • Explain the concept of imperfect proof test coverage and its impact on the facility
  • Describe the requirement to collect failure rate data and failure classification
  • Recognize the requirement for development of an approved vendors list for safety instrumented systems and how this relates to prior use
  • Describe the purpose of demand tracking and the associated requirement for root cause analysis
  • Justify testing deferral from a risk standpoint
  • Explain the impacts of bypassing independent protection layers from a risk standpoint

You will cover:

  1. Regulatory / Corporate Requirements for adoption of IEC61511
  1. Introduction to Risk Analysis
  1. Introduction to SIF / IPL requirements
    1. I've picked a SIL now what?
    2. I've picked an IPL now what?
    3. Introduction to SIL Verification Calculations
    4. Introduction to SRS and C&E requirements
    5. Safe Operating Limits Tables
    6. Process Safety Time
  1. Testing Program Development
    • Prior Use Justification vs. certified devices
    • What's a "good" test plan look like
    • Calibration requirements
    • Development of Test Plans
    • Introduction to Proof Test Coverage
    • Failure Classification and Data Collection
    • Calculation of actual failure rates
    • Justification of Testing Deferral
    • Mean Time To Repair
  1. Functional Testing versus Commissioning Exercises
  1. Bypassing of SIFs/Override Risk Assessments
  1. Demand Rate Data Collection w/ Root Cause Analysis
  1. Capital Projects Requirements with regards to SIS and O&M
  1. Management of Change
  1. Process Safety Metrics
    • Leading indicators
    • Lagging indicators
    • Process safety performance improvements
  1. Safety Audits
  1. Functional Safety Assessments
    • Stage 1
    • Stage 2
    • Stage 3
    • Stage 4
    • Stage 5

Classroom/Laboratory Exercises:

  • Hazard Recognition
  • Test Plan Development
  • Constructability Recognition for Testing
  • SIL Calculations
  • Management of Change
  • Prior Use Justification

Not sure this particular course is for you?
pre-instructional survey is available for you to evaluate your level of understanding of the course material and to show you the types of questions you'll be able to answer after completing the course.