Kenexis - Functional Safety Podcast
The Kenexis Functional Safety Podcast is hosted by Ed Marszal, President and CEO of Kenexis, a technical safety consultancy for the chemical process industry. It explores the IEC 61511 standard by examining the significance of each word and providing detailed interpretation and application guidance. Marszal draws on decades of experience in safety instrumented systems and his work on the ISA 84 committee since 1994. The inaugural season combines technical insight with personal stories from his career and committee discussions.
Episodes
S1E56 Clause 13.2.4 to 13.2.7
During the Factory Acceptance Testing (FAT), you're going to find issues. You can’t fix them on the spot— you need to trace each one back to wherever it originated in the safety lifecycle and correct everything downstream from that point.
S1E55 Clause 13
Factory Acceptance Testing is where Ed Marszal picks up in Clause 13, starting with an admission: the clause title may be wrong, since 13.2 is called Recommendations when every other point-two clause in the standard states requirements. Scope matters here FAT applies to the SIS logic solver, the engineered, customized subsystem, not off-the-shelf field devices like a pressure transmitter. Ed works
S1E54 12.5 and 12.6
Clause 12.5 closes out the software section with the meat of application program testing: verification planning tied back to Clause 7, an independent competent-person review, and nine bullet points covering conformance testing, exercising all parts of the program, representative data ranges, negative testing, timing and sequence checks, communication overload stress tests, and integration with the
S1E53 12.4.3 and 12.4.4
The best and safest way to write software is to break things down into tested reusable modules...
S1E52 12.4
At the risk of saving you from hours of unnecessary work, in our latest episode, we tackle a surprisingly common habit: trying to do application program design and implementation at the exact same time. Tune in to hear why this happens, why it's a problem, and how to stop doing it!Grab your headphones and let's streamline your workflow!
S1E51 12.3.4 pt2 to 12.3.5
Designing software comes before writing it. We're still inthe design phase and will be for a bit…Listen in to this episode as the discussion of this topic continues.
S1E50 12.3
To clarify, the standard separates application program design from its actual implementation. It feels like a bit much…Join us for our 50th episode as this is discussed in more detail!
S1E49 12.2.6 to 12.2.9
The startup sequence of a Safety Instrumented System (SIS)represents a critical vulnerability phase, as it triggers initialization code that rarely executes during steady-state operation.Join us as this important topic is discussed in this episode.
S1E48 12.1 to 12.2.5
The first technical safety standard ISA84 didn’t talk about programming in it at all. So, we decided when we added it, wewould wildly over complicate the situation…
S1E47 11.9.3 to 11.9.5
Do not incorporate human failure into your SIL verification calculations, it will actually lead you to do the wrongthing.In this episode, this important topic is covered by our industry expert as he discusses these sections and shares his vast knowledge and experience.
S1E46 11.9.1 and 11.9.2
When it comes to SIL verification calculations, we look at Clause 11.9. It’s appropriately titled 'Quantification of Random Failures'…putting the focus on 'random' right there in the name.
S1E45 11.8.4 to 11.8.6
A device should never remain in bypass indefinitely. Bypass duration must be time-limited, and appropriate compensating measures must be implemented. Listen in for more information and thoughts on this important topic.
S1E44 11.8.1 to 11.8.3
The design shall allow for testing of the SIS either end to end OR in segments meaning you could test one piece at a time, but when you do that, you have to be very careful…Tune in as this topic is explored in greater detail, covering Sections 11.8.1 to 11.8.3 in this episode.
S1E43 11.7.3
Many users of generic, off-the-shelf PLC logic solvers for Safety Instrumented Systems are surprised to learn that maintenance and engineering interfaces are not permitted to be connected while the process is in operation.Join us as section 11.7.3 is discussed in more detail.
S1E42 11.7.2
Bypasses and resets are two standard data elements routinelytransmitted from the BCPS to the SIS, and this communication must be done safely…Listen in for more information on this section.
S1E41 11.7.1 and 11.7.4
You can transfer data to and from the Safety Integrated System (SIS), but your design must prevent an outside failure from causing an internal SIS failure.In this episode, we dive into the crucial world of secure data transfer for SIS.
S1E40 11.6
Don't let the certificate distract you. Your role as an instrumentation and control engineer requires continued diligence. The work still needs to be done!
S1E39 11.5.4 through 11.5.6
Did you know that you can install Programmable Logic Controllers (PLCs) based on prior use without being certified? Sounds easy, right? Think again!While they are exempt from formal certification, we reveal why achieving full compliance with installation and safety requirements is often an extremely difficult, if not impossible, hurdle for engineers. Tune in to learn why relying on prior use might
S1E38 11.5.1 through 11.5.3
The devices you use in your safety instrumented systems DO NOT have to be certified! We're cutting through the noise to give you the facts on what truly matters for functional safety. In this episode we discuss the actual requirements—the principles, standards, and engineering practices—that dictate a device's suitability.
S1E37 11.4
You achieve a given SIL target by running a calculation that verifies you achieved the proper probability of failure on demand, yet the standards committee doesn’t trust to do that properly….
S1E36 11.3
How should the safety instrumented system respond to adetected failure? Well, it will respond however you want it to respond…
S1E35 11.2.12 to 11.2.14
Unscrupulous equipment vendors often bury critical safety information in a product's safety manual to get their products certified. Therefore, it's essential to read the manual thoroughly to uncover any potential hazards.Join us as Ed discusses this topic in more detail.
S1E34 11.2.11
Energize to trip or de-energize to trip, that is the question… and the answer is… you can do whatever you want…
S1E33 11.2.9 to 11.2.10
A device used by the SIS shall not be used by the BPS (unless that’s what you really want to do) ….Join Ed to hear his thoughts, experience and insights as he digs further into Clause 11.2.9 to 11.2.10.
S1E32 11.2.8
In this week’s podcast Ed discusses clause 11.2.8, which is all about manual shutdowns. The session ranges from the apocryphal or true OG manual shutdown that traces back to the Manhattan project - the SCRAM - to a second hand story of why a toilet malfunction generated the requirement that manual shutdowns be independent of the logic solver.
S1E31 11.2.6 to 11.2.7
Once the Safety Instrumented System brings the system to a safe state, it should remain in that state until an operator manually intervenes.This topic is explored in more detail with a discussion of clause 11.2.6 to 11.2.7 of the IEC 61511 standard.
S1E30 11.1 to 11.2.5
We've finally arrived at clause 11 titled SIS Design and Engineering, which is where the core work happens! This episode, the discussion focuses on sections 11.1 to 11.2.5.
S1E29 10.3.3 to 10.3.6
After several weeks of laying the groundwork on SafetyRequirements Specifications (SRS), we're back for a more focused discussion.This episode, we're zeroing in on SRS specifically for application software by discussing clauses 10.3.3 to 10.3.6
S1E28 – 10.3.2 bullet 24-29
Wow! There are a lot of things in the safety requirements specifications clause. It has taken us several episodes, but we finally get to finish up the discussion on this section.
S1E27 – 10.3.2 bullet 19-23
In this episode, we dive deeper into the requirements forstarting up and re-starting Safety Instrumented Systems (SIS). Wasn’t this already covered in bullet point 16? Join us as we revisit Clause 10.3.2 to clarify any confusion and unpack what’s really required when bringing SIS back online.
S1E26 - 10.3.2 bullet 15 - 18
“Fail safe” is a common term—and it sounds great. Who wouldn’t want things to fail safe? But here’s the thing: can we ever really guarantee that? Join us as we unpack what “fail safe” really means, why it’s not always as foolproof as it sounds, and what that means in the real world.
S1E25 - 10.3.2 bullet 12 – 14
When a shutoff valve is told to close, the movement is just the beginning. Behind that simple action lies a complex web of consideration. In today’s episode, we’re diving into what really happens when a valve is commanded to shut, and why there’s so much more to it than meets the eye.
S1E24 - 10.3.2 bullet 9 to 11
Process Safety Time is one of the most complex andchallenging aspects of the 61511 standard, which is why it will be shifting to MERT.
S1E23 - 10.3.2 bullet 4 to 8
In this episode, CEO of Kenexis Ed Marszal, continues his discussion of Safety Requirements Specifications as found in clause 10.3.2 of the IEC61511 standard.
S1E22 - 10.1 to 10.3.2 bullet 3
In this episode, we’re diving into the concept of Safety Requirements Specification. What exactly does it mean, and why is it more complex than you might think? Stay tuned as we break it down and explore its importance in functional safety.
S1E21 - 9.3 to 9.4
In this episode, we explore an important question in the world of functional safety: Can a basic process control system be considered a valid protection layer?
We’ll dive into the circumstances under which it may be appropriate to give it credit, and discuss the factors that determine how much credit should be assigned.
Stay tuned as we unpack this critical topic and provide insights to help you
S1E20 - S9.2.5 to 9.2.9
If your risk analysis has led you to conclude that you need
a SIL 4, that’s a red flag. It’s likely time to go back to the drawing board and reassess.
In today’s episode, we’ll explore why this might be the case and how to approach functional safety to avoid overestimating risk levels.
S1E19 - S9.1 to 9.2
Clause 8 and Clause 9 in the IEC 61511 standard are both required to obtain your SIL targets.
S1E18 - 8.2.2 to 8.2.4
In our latest podcast episode, we dive into how the basic process control system introduces complexities into risk analysis, starting right from the hazard and risk assessment stage. Tune in for insights into navigating these complexities.
S1E17 - 8.1 to 8.2
In this episode, we kick off our exploration of the process
safety lifecycle by diving into hazard and risk analysis. After some thoughtful pre-discussion, we lay the groundwork for understanding the essential
components of safety management in industrial settings.
Join us as we unpack the critical steps involved in
identifying and assessing risks to ensure safer operations.
S1E16 - Section 7
Validation is a final physical test on the completed system,
but verification is the step by step back-checking of each individual activity.
S1E15 - Section 6
The SIS safety life cycle outlines all the activities involved in designing safety instrumented systems to achieve functional safety, as detailed in Clause 6.
S1E14 - 5.2.6.2 and 5.2
Functional safety assessments and functional safety audits serve distinct purposes. Audits evaluate the ongoing operations of a facility across all areas, while functional safety assessments focus specifically on a single project.
S1E13 - 5.2.6.1.1 to 5.2.6.1
Many people misunderstand the fundamental concepts of assessment and auditing. It's not about verifying whether the work was done correctly; it's about ensuring that the work was carried out according to the plan or the way you said it would be done.
S1E12 - 5.2.5
Having just "a plan" for functional safety isn't enough;
you need to implement and monitor every step to ensure it gets done.
In this episode, Ed Marszal, President of
Kenexis, discusses Clause 5.2.5 of the IEC 61511 standard.
S1E11 - 5.1 to 5.2.4
Management of functional safety is the key to a good safety instrumented system.
In this episode, Ed Marszal, President of Kenexis, discusses Clause 5.1 through 5.2.4 of the
IEC 61511 standard.
S1E10 – 3.2.77 to 4.0
In this episode, Edward Marszal, President of Kenexis finishes his discussion of the definitions section of the
IEC 61511 standard.
S1E9 - 3.2.65 to 3.2.76
How many definitions does it take to define what a safety instrumented function is? Surprisingly, it’s more than you would think.
In this episode, Ed Marszal, President of Kenexis, discusses Clause 3.2.65 through 3.2.76 of the
IEC 61511 standard.
S1E8 - 3.2.57 to 3.2.64
Safety is the freedom from risk that is not tolerable, but what is risk and how do you know it is tolerable?
S1E7 - Clause 3.2.43 through 3.2.56
In this episode, Ed Marszal, President of Kenexis, discusses Clause 3.2.43 through 3.2.56 of the IEC 61511 standard.
S1E6 - Clause 3.2.35 through 3.2.42
In this episode, Ed Marszal, President of Kenexis, discusses Clause 3.2.35 through 3.2.42 of the IEC 61511 standard.
S1E5 - IEC 61511 Clause 3.2.17 through 3.2.34
In this episode, Ed Marszal, President of Kenexis, discusses Clause 3.2.17 through 3.2.34 of the IEC 61511 standard.
S1E4 - 3.2.6 through 3.2.16
In this episode, Ed Marszal, President of Kenexis, discusses Clause 3.2.6 through 3.2.16 of the IEC 61511 standard.
S1E3 - Clause 2 through 3.2.5
In this episode, Ed Marszal, President of Kenexis, discusses Clause 2 through 3.2.5 of the IEC 61511 standard.
S1E2 - 61511 1g through the end of Clause 1.
In this episode, Ed Marszal, President of Kenexis, finishes his discussion of Clause 1 of the IEC 61511 standard.
S1E1 - 61511 Clause 1 through 1f
In this first episode of this podcast, we are going to focus on the IEC 61511 standard, Clause 1 through 1f– Functional Safety – Safety Instrumented Systems for the Process Industry Sector, doing a deep dive into every word of the content of the standard. In addition to the content of the standard, I will also be providing a lot more depth of information on what the standard means by what it says
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