Preface

Risks and hazards are a part of everyday life. And it is our natural tendency to make
decisions after calculating risk for the action. Looking at a long distant traffic light, a
driver controls the speed and applies brake at the correct time and place to stop the
car within stop line without any jerking. However, the person may not be safe for
long! In the area of technology, too, there are hazards and risks everywhere; nothing
is totally free from hazards or risk. In all of industrial facilities, process plants, civil/
architectural construction sites, transportation systems, aerospace, space craft e
even for a financial decisions there will be hazards in different forms. Accordingly,
there will be associated risks in different forms and in varying nature. Therefore, it
is obvious that hazard analysis is an absolutely necessity in all spheres of life.
The book has two parts; one part is mainly related to hazard analysis methods
applicable for all disciplines of engineering. The other part is based around recent
IEC standards for life cycle analysis for safety instrumented systems (SISs). The
book covers all major hazard analysis methods and safety instrumentation applicable
for all industrial plants. The book enjoys granted permission from IEC Switzerland to
utilize some figures from their standards IEC 61508 and 61511; the premier interna-
tional standards for E/E/PEs for SIS and life cycle methods (duly acknowledged). In
view of the total coverage of the book, international society IChemE has included
the book in their series of technical books.
There are a number of books available on hazard analysis as well as quite a few
books on SIS. However, there are hardly any technical books where people get the
tastes of both in a single book. Also, the majority books are with theoretical approach
with huge mathematical details, or only practical details without any basic approach.
This book endeavors to act as a balancing means between two extreme lines of
thinking, giving a comprehensive approach toward hazard analysis as well as safety
instrumented systems. The book takes into account basic mathematics, but more
emphasis has been put on physical explanations. Hazard analysis covers both qualita-
tive type, word-based systems, and quantitative systems (including human errors anal-
ysis) have also been covered comprehensively with automated processes for hazard
analyses. Hazard analysis part will help instrumentation practicing engineers in
participating in various hazard analysis processes. For each case, both mathematical
approaches as well as physical explanations have been put forward. Step-by-step
SIS determination from various failure modes, reliability, and safety integrity level
(SIL) calculations and selections from various approaches, for example, risk matrix,
risk graph, etc. help to arrive at correct and appropriate SIL calculation. The book
comprehensively discusses each and every stage in different phases, that is, all the
aspects of life cycle process mentioned in IEC 61508 and 61511 for E/E/PEs, with
respect to continuous process and manufacturing industries. The book also covers
safety systems of batch process in line with ISA 88. It also includes an alarm as an
independent protection layer (IPL), area classification including explosion protec-
tion, fire and gas system, process shutdown (PSD) and emergency shutdown

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xx Preface

(ESD). Finally, a discussion on SIS would be incomplete unless certification methods,

FMEDA, proof testing, and partial stroke testing, etc. are not covered.
Detailed discussions at component level starting from sensors, safety field bus, safe
logic solvers, and final control elements are a unique addition to the book. The book
also covers the security aspects of various networks, viz. firewalls and zone-conduit to
name a few, which is also another unique feature of the book. The book also covers
application of SIS in various plants covering fossil fuel power stations, nuclear power
stations, oil and gas sector such as upstream, midstream, refinery, and petrochemicals.
There have been supplementary data and information on statistical approaches,
embedded controls, and cost impact and life cycle cost analysis to take care of
advancement in technology and systematic approach toward the problem.
The book is primarily meant for working professionals but budding (fresh) engi-
neers who started their career in industrial plants and process plants will be equally
benefitted. The book covers both hazard analysis and safety instrumentation from
early stage to most advanced stage. It would be beneficial to engineers from other dis-
ciplines also in almost all industrial sectors e with special reference to process indus-
tries. For this comprehensive coverage, the book has been selected by IChemE in
their series of technical books.