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And the survey says?

A recent “Market Intelligence” report on Safety Instrumented Systems (SIS) had me shaking my head.  What really surprised me about their reported findings was on the heavily debated topic of SIS independence.  For those who like reading my BLOG, but are not (yet) process safety gurus, please allow me to explain. 

For the past several years, people from our industry (manufactures, end users, and consultants) have been debating the merits of keeping your basic process control system (BPCS) completely separate from SIS.  Some might think of it as the equivalent of combining your car’s emergency brakes with its conventional brakes.  You can easily imagine the benefits for keeping them separate.  But for some, they argue that the added cost and complexity isn’t worth it, as today’s cars conventional brakes are good enough (when’s the last time you had to yank on your emergency brake handle because your brake pedal didn’t respond?).      

Now back to the survey results. 

I was astonished to see that “38% of respondents said the SIS should be independent; whereas 62% said it was okay to have both systems on the same backplane.”   Wow, could our industry really be warming up to the integrated concept that quickly?   Say good bye to the emergency brake concept, and to all those small dedicated SIS vendors? 

My experience had me thinking just the opposite, so I dug a little deeper, and discovered just how the survey posed their question. 

Should the SIS be independent, or can it be on the same backplane with the BPCS? 

Respondents could only respond with a YES or NO?

That’s like saying:

Should your cars emergency brakes be independent, or can they be combined with your car’s conventional brakes?

There’s just NO way to answer this (try it).  If you want I will e-mail you the full survey (it was done by a very reputable trade journal).  Just let me know your thoughts on integrating SIS with BPCS.

Published Friday, April 20, 2007 10:18 AM by Charles Fialkowski

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# re: And the survey says?

Charlie, I don't like your analogy that integrated control & safety is like combining emergency brakes with conventional brakes. That analogy implies 100% common cause between the 2 systems and thus a single layer of protection. That is NOT what integrated control & safety means to most people. The major suppliers of integrated control & safety systems (e.g. Honeywell, Siemens, ABB, Emerson & Yokogawa) all provide solutions that use dedicated controllers and I/O for the safety system. Some offer an integrated engineering environment and some offer integrated communications but they are all certified by TUV such that the non-safety components are non-interferring, that is a failure of the non-safety components will not interfere with the ability of the safety system to perform it's safety function. Properly implemented, in these integrated architectures the DCS and the Safety system can be treated as independent layers of protection. A better analogy is this. Imagine if, in the past, auto manufacturers didn't provide emergency brake systems. So, if you wanted one you had to take your car to a special niche supplier to have an aftermarket emergency brake system installed. They worked fine but they were costly and complex to install and didn't integrate well into the car. Maintenance was was costly because you had to go to separate garages for parts and service. Over time, the automakers decided to offer an emergency brake system as an option in their vehicles. These systems operated just like the aftermarket systems and complied with the same rigorous design and testing. Customers could now have the advantage of getting the auto with the emergency brake system installed and nicely integrated into the car. They could also go the same garage for service on both. The "compromise" is that while the brake systems are independent they were designed, manufactured and installed by the same supplier. They may even have some common parts. This is an insignificant compromise when compared to the benefits. Especially if an independent 3rd party safety agencies have evaluated the risks and certified the design to be safe. I argue that this scenario is perfectly analagous to what is occurring today. The major automation suppliers, like the major automakers, have all introduced an integrated safety systems when in the past you had to go to a different, specialty supplier. How would you expect the niche suppliers of the aftermarket emergency brake systems to respond? Of course, they're going to aggressively defend their market! How? By trying to scare consumers by saying they are putting their loved ones at risk by trusting an emergency brake system installed by the same manufacturer as the conventional brake system. This is exactly what is happening today with programmable safety systems. The niche, specialty suppliers are aggressively defending their market. Who could blame them? But, then again, who would continue buying an aftermarket emergency brake system when they could get one with their car?
Friday, April 20, 2007 6:32 PM by B. Real

# re: And the survey says?

Very nice analysis.
Monday, April 23, 2007 10:50 AM by Charles Fialkowski

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