10/3/22, 5:11 PM Free PFD calculator tool | functional safety | SIL | Consiltant

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PFD Calculator

PFD Consiltator
Introduction
Critical instrumental systems prevent hazardous events of situations in which people could
be injured (or worse) and/or the environment could be polluted.

The standards, IEC 61511:2017 and IEC 61508:2010, define the criteria for Safety
Instrumented Functions (abbr. SIFs).

A SIF shall be fit for purpose preventing the identified hazard.

The integrity level of a SIF, defined as SIL 1, 2, 3 or 4, provide risk reduction.

A SIF may be compromised by systematic failures and/or random hardware failures.

Systematic failures shall be prevented by:

An adequate functional safety management system

Competent personnel

Fabricated instruments/components shall meet the systematic capability requirements

(e.g. SC-3).

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The technical integrity of a SIF is depending of:

Independency of the SIF

Architectural constraints of the sensor subsystem, the logic solver and the final
elements
Probabilistic constraints of the SIF (average probability of failure on demand,
PFDavg).

During a SIL verification the integrity of the SIL safeguard is checked against the required
integrity.

Average probability of failure on demand – PFDavg

In the process industry sector, the demand rate is often less frequent than once per year.
The following PFDavg values are required:

SIL 1               PFDavg < 10-1

SIL 2               PFDavg < 10-2

SIL 3               PFDavg < 10-3

SIL 4               PFDavg < 10-4

IEC 61511 provides the following information:

Several modelling approaches are available and the most appropriate approach is a matter
for the analyst and can depend on the circumstances. Available means include:

– cause consequence analysis;

– reliability block diagrams;

– fault-tree analysis;

– Markov models;

– Petri nets models.

PFDavg is depending on:

Dangerous Detected and Undetected failure rates of the instruments and

components, λDDand λDU
Redundancy configuration
Common cause β-factor in case of redundancy configuration
Proof test interval
Proof test coverage
Lifetime of the SIF
Mean Time to Restoration
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Time needed for tests

But how relevant are all these variables and how sophisticated should be the modelling
approach?

With powerful, sophisticated PFD calculation software, the PFDavg can be calculated very
precise. However, the outcome stays uncertain while the following factors are just raw
estimates:

Common cause ß factor

Proof test coverage and lifetime

A frequently used basis to determine ß factors is the informative Annex D  of IEC 61508:6.
By filling in scores, a ß factor will be determined. ß= 5% is almost standard. According to a
thoroughly performed study of SINTEF, the actual common cause factor is in between 10 –
15 % (reference can be made to ‘Common cause failures in safety instrumented systems’,
final version, 20 May 2015).

It is the opinion of Consiltant BV that for SIL 1 and SIL 2 SIF’s it does not
make sense to use complex sophisticated software to calculate
precisely the PFDavg if other relevant factors are just estimates.

A minimal common cause Beta factor of 10% is to be recommended.

The correct performance of proof tests is critical! Poor proof tests are never acceptable
although it can be modelled in de PFDavg calculation (e.g. a proof test coverage factor of
75%). A low proof test coverage may never be compensated by more frequent poor proof
tests in order to meet the PFDavg target.

It is the opinion of Consiltant BV that a proof test procedure shall always

be complete and detailed. Personnel shall be competent in order to
detect and restore dangerous undetected failures and systematic
failures.

PFD Consiltator
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Consiltant BV developed PFD Consiltator, an Excel based tool in order to calculate the
PFDavg.

PFD Consiltator can be downloaded here.

PFD Consiltator consists of a simple and more advanced calculation methode. The simple
calculation is based on the following formulas:

Proof test coverage is not taken into account. The test procedure is assumed to be 100%
correct.

In the advanced version, the proof test coverage is included in the calculation. The expected
lifespan / mission time of the selected components must also be included in the analysis.
The calculation is based on the methods described in IEC-61508-6 and VDI/VDE 2180 (part
3).

Download the Consiltator.

Disclaimer
The PFD Consiltator for calculating the PFDavg according to IEC 61508 and VDI/VDE 2180 has been carefully prepared.
Nevertheless, no liability is assumed for the calculated results and their correctness. The calculation of the PFDavg of
the respective safety function is the sole responsibility of the user.

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Consiltant BV
Consiltant BV provides Process Safety Consultancy. The strengths of Consiltant BV
are knowledge and experience of;

Various methods for identification of hazards (HAZOP, FMEA, What If).

Risk assessment methodologies (Risk matrices, Risk graph, LOPA, SIL).
Risk-reducing measures.
Verification and validation of safe guards. Ensuring that the right safeguards
are realized. Verification of testing procedures.
Simulation of PLC application programs.
Implementation of functional safety management system

Assignments are carried out for the chemical industry, oil & gas industry, food industry
and the energy supply. At home and abroad.

Contact
info@consiltant.com
+31 6 55 82 11 95

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