RELIABILITY & RISK ASSESSMENT SAFETY INTEGRITY TRAINING COURSES Tel: 01732 352532 Fax: 01732 360018 Technis.djs@virgin.

net www.technis.org.uk

26 ORCHARD DRIVE, TONBRIDGE, KENT, TN10 4LG.

THE CERTIFICATE IN RELIABILITY & FUNCTIONAL SAFETY

PROSPECTUS
Reliability technology and its mathematics Risk assessment techniques IEC 61508 Functional Safety Requirements

The course, which leads to the certificate in reliability and functional safety, is accredited by The International Academy for Quality Certification and approved by The Institution of Gas Engineers and Managers for CPD. It is provided by Dr David J Smith who has had over thirty years of experience in reliability and risk assessment and inhouse training courses. David has written and updates a range of textbooks and software packages on the above topics. Reliability Maintainability & Risk 7th edition is now widely acknowledged as the standard work on this subject. David continues to be an authority in his field and chairs the IGEM panel which produces guidelines on safety related programmable systems. He is a Past President of the Safety and Reliability Society.

The certificate is aimed at those requiring an in-depth knowledge of the subject such that they may become lead practitioners within an organization or embark on consultancy in the field. It is envisaged that participants will already have a numerate professional qualification (see section 1). Study involves a combination of: Pre-course study 4 days formal teaching including supervised worked examples (section 3) 4 distance learning assignments supervised and assessed by Technis
____________________________Dr David J. Smith BSc,PhD,CEng,FIEE,FIQA,HonFSaRS,MIGasE_______________________

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(section 4) A supervised project assignment with a Technis approved mentor (section 5) Two, 2 hour examination papers marking independently reviewed (section 6) Award of the certificate is dependent upon 100% attendance, satisfactory assessment of all assignments, the submission of a project report (4,000 words) and a pass in both the Reliability and Functional Safety examination papers. Details are in the following pages:

____________________________Dr David J. Smith BSc,PhD,CEng,FIEE,FIQA,HonFSaRS,MIGasE_______________________

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1. 1.1

PURPOSE AND ENTRY REQUIREMENTS Purpose The course is aimed at engineers who require an in-depth knowledge of reliability and safety technology, to a level that enables them to carry out assessments of data, systems and equipment with little or no recourse to 3 rd party assistance. It will enable them to supervise others engaged in reliability and functional safety work, to provide the focal point of expertise within an organization, or to embark on consultancy. It will also provide them with the background to be proactive in further study and in keeping abreast of the topic. 1.2 Entry Requirements

a)

Either: Chartered Engineer or Member of the Safety and Reliability Society or b) A numerate degree or HND or HNC or equivalent qualification together with a professional review with Technis, as to their suitability to undertake the course. 2. COURSE MATERIAL The leading text on reliability engineering: Reliability, Maintainability and Risk, 7th Edition, D J Smith, Elsevier (Butterworth Heinemann) ISBN 07506 6694 3. Functional Safety A straightforward explanation of IEC61508: Functional safety, A straightforward guide to IEC 61508 2nd edition, 2004, Smith DJ and Simpson KGL, Butterworth Heinemann ISBN 07506 6269 7 PhD work on Common Cause failure Modeling: BETAPLUS Version 2.0, User's Manual ISBN 09516562 5 2. The Technis reliability data base: FARADIP.THREE Version 6.0 Failure Rate Data Base, Users manual ISBN 0 9516562 3 6. A Fault Tree package: TTREE Version 3.2, User's Manual, ISBN 09516562 4 4. An RCM package for Optimum Replacement and Spares strategies: COMPARE Version 2.1, Users Manual ISBN 0951656228 Course notes: Lecture slides, notes and worked examples.

____________________________Dr David J. Smith BSc,PhD,CEng,FIEE,FIQA,HonFSaRS,MIGasE_______________________

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3. THE 4 DAY COURSE

DAY 1
08.30 INTRODUCTION AND OBJECTIVES - Introduction of participants - Brief review of the programme - Discussion of specific requirements USES AND APPLICATIONS - Reliability, profitability, hazards - Maintenance and the field - Safety Integrity - Optimum reliability - Need for both Quantitative v Qualitative approaches TERMS AND JARGON - Parameters and their pitfalls - Simple relationships between parameters - Some acceptable approximations LUNCH - Exercises on manipulating reliability parameters 13.30 INTERPRETING FAILURE DATA - Inference and Confidence Levels - Constant Failure Rate Data - Exercises - Pitfalls (discrimination) in Test Plans - Exercise - Variable Failure Rates - Exercise - PC Weibull Exercise - Optimum replacement intervals DISCUSSION, RECAP CLOSE

10.30

11.15

12.15

16.00 16.30

DAY 2
09.00 FAILURE RATE DATA - Comparison of Sources - Accuracy and Tolerance - FAILURE RATE RANGES USING FARADIP DATA BASE - Comparison of FIELD, WARRANTY and TEST data (examples) - FARADIP demonstration and familiarisation RELIABILITY PREDICTION - Reasons for carrying out predictions - Limitations - Initial summary of methods (FMEA, FTA, Block Diagram, Simulation)
____________________________Dr David J. Smith BSc,PhD,CEng,FIEE,FIQA,HonFSaRS,MIGasE_______________________

09.45

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10.15 10.30

COFFEE FAILURE MODE AND EFFECT ANALYSIS - Uses (failure rates, diagnostic coverage) - Practical FMEA Exercise RELIABILITY MODELLING - Series and Parallel Configurations - Exercise - Systems with Repair - Exercise LUNCH - Repeat of exercise as a Fault Tree - Exercise with TTREE (cutsets and importance) - Common mode failure modelling - Causes and Defences - Familiarisation with Betaplus tool - Diagnostic coverage HUMAN FACTORS - Quantification methods - Exercise using spreadsheet version of HEART and TESEO EXERCISE (Case Study) - Introduce material

11.15

12.15 13.00

15.15

16.00

DAY 3
09.00 11.00 11.30 - Participants work on case study (incl CCF with Betaplus) - Solution to Case Study FIELD TRIALS AND RELIABILITY GROWTH - CUSUM and Duane - Practical Exercises MAINTAINABILITY - Down time and repair time prediction LUNCH RELIABILITY CENTRED MAINTENANCE (RCM) - RCM techniques - Optimum replacement, spares & proof-test - Exercise EXAMINATION RELIABILITY THEORY

12.0 12.15 13.00

14.00

____________________________Dr David J. Smith BSc,PhD,CEng,FIEE,FIQA,HonFSaRS,MIGasE_______________________

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DAY 4
08.30 FUNCTIONAL SAFETY (Establishing SIL targets) - Safety-integrity targets - Need for quantitative AND qualitative assessment - Structure of 61508 - SIL Exercises 1-2 (Target low demand SIL) - SIL Exercise 3 (Target high demand SIL) - Risk graph & matrix approaches (Exercise 4) - Justifying non-safety related assumptions - ALARP (Exercise 5)

9.30 SAFE FAILURE FRACTION - Revisit FMEA 09.45 THE ASSESSMENT EXERCISE (participants) - Random Hardware Failures - ALARP - Safe failure fraction - Recap on the The Exercise - Additional exercise if time permits - or real examples from participants Parts 2 & 3 of IEC61508 - Qualitative Requirements - Life-cycle activities and requirements - Acquired sub-systems - Demonstration of proven in use - Functional safety capability - Framework of certification Review of 2nd tier sector specific guidance EARLY LUNCH EXAMINATION FUNCTIONAL SAFETY SPECIFIC CALCULATIONS OR ITEMS REQUESTED BY PARTICIPANTS CLOSE

10.00

11.00 11.15 12.15 14.30 15.00

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4. THE DISTANCE LEARNING ELEMENT Early in the course the candidate will discuss, with Technis, 4 areas of particular interest. He/she will be set the task of reading and researching those 4 areas and writing a 1,000 word report on each. Satisfactory performance will be required in order to pass the certificate course. Minor remedial actions can be addressed and a revised report submitted as appropriate. This element must be completed within 6 months of the examination for a certificate to be awarded. One of the four areas must be of a mathematical nature. One of the four areas must involve human factors One of the four areas must involve qualitative activities aimed at systematic failures One of the four areas may involve a totally free choice of topic 5. THE SUPERVISED PROJECT The candidate will be required to work for 3 days with/for either Technis or a Technis approved mentor. He/she will carry out an agreed set of tasks (for example conducting a HAZOP, constructing and quantifying a fault tree model, carrying out a functional safety audit). The candidate will submit the work/report (4,000 words) for evaluation. The mentor will submit a written report, on the candidates work, for discussion with Technis. Satisfactory performance will be required in order to pass the certificate course. Minor remedial actions can be addressed and a revised report submitted as appropriate. This element must be completed within 6 months of the examination for a certificate to be awarded. 6. THE EXAMINATION This will be set by, and normally invigilated by, Technis. The marking will be independently reviewed by a competent expert in the field. Failed candidates may re-sit at the discretion of Technis. Project work and distance learning must be completed within 6 months of the examination. Paper 1 Reliability Engineering A 2 1/2 hour paper setting mathematical problems in data analysis and reliability modeling. A 65% pass mark is required. A 75% pass will enable the candidate to be considered for a distinction which will depend upon the performance on the other elements of the course. Paper 2 - Functional Safety A two hour paper setting mathematical problems in safety integrity quantification, ALARP demonstrations, system architectural requirements and qualitative life-cycle activities in the design and overall life cycle. A 65% pass mark is required. A 75% pass will enable the candidate to be considered for a distinction which will depend upon suitable performance on the other elements of the course. A Distinction requires a minimum of 75% in each paper and an average of 80%.
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7. EVIDENCE A file will be kept for each candidate recording the course work reports, project documents and examination papers. It will be held available for 5 years and can be made available (with the permission of the candidate) as evidence of achievement. 8. THE CERTIFICATE Illustrated overleaf.

____________________________Dr David J. Smith BSc,PhD,CEng,FIEE,FIQA,HonFSaRS,MIGasE_______________________

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26 ORCHARD DRIVE, TONBRIDGE, KENT, TN10 4LG. Tel: 01732 352532; Fax: 01732 360018 Technis.djs@virgin.net

CERTIFICATE IN RELIABILITY and FUNCTIONAL SAFETY ..SAMPLE ONLY..

(Approved by IGEM for CPD: Accredited by IAQC)

This is to certify that

Mr Arthur N Other
Has satisfied the Examination and Course-work requirements of the Technis certificate in Reliability and Functional Safety

(With Distinction)
The course has involved lectures, worked examples, project assignments and two formal examinations covering: Reliability parameters and their manipulation Statistical data analysis, test plans and reliability growth Reliability modelling & quantification Reliability centred maintenance IEC 61508 Functional Safety requirements Hazard identification and SIL targeting Assessment of safe failure fraction Demonstration of ALARP Control of systematic failures Life-cycle activities & Functional Safety Capability

Signed:(31 May 2006)

Dr David J. Smith BSc,PhD,CEng,FIEE,FIQA,HonFSaRS,MIGasE ____________________________Dr David J. Smith BSc,PhD,CEng,FIEE,FIQA,HonFSaRS,MIGasE_______________________

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(the candidates project work is available for inspection, subject to permission)

PRE-COURSE STUDY
The following study is essential for candidates who wish to follow the certificate course with 3 days (rather than 4 days) formal teaching. The commitment in time is entirely up to the candidate but a suggested budget of 10 hours is credible. Reliability, Maintainability and Risk - 7th Edition Chapter 1: (suggested 1 hour) Read for a general background Chapter 2: (suggested 2 hours) Read thoroughly and make sure you can prove how , MTBF and R(t) are related and how the special case of constant failure rate is derived. If you can do this you will be able to answer one of the exam questions Do the exercises at the end WITHOUT looking at the answers. Chapter 4: (suggested 1 hour) Read for general in interest. Take special note of 4.3 and 4.4 Chapter 5: (suggested 2 hours) Read through quickly. Then read 5.1, 5.2 and 5.5 thoroughly and do Exercise 1 and 2. If you can do this you will be able to answer one of the exam questions Then read 5.6 thoroughly and do Exercise 3. If you can do this you will be able to answer one of the exam questions. Chapter 6: (suggested 2 hours) Read thoroughly and try Exercise 2 using the Fig 6.1 graph paper, In the exam you will be allowed to do this using COMPARE. Functional Safety A Straightforward Guide to IEC 61508 - 2nd Edition Chapter 1: (suggested 1/2 hour) Read for a general background Chapter 2: (suggested 1 hour) Read and do Exercises 1 to 3

____________________________Dr David J. Smith BSc,PhD,CEng,FIEE,FIQA,HonFSaRS,MIGasE_______________________

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BUTTERWORTH - HEINEMANN

RELIABILITY, MAINTAINABILITY AND RISK

Practical Methods for Engineers

7th Edition
Dr David J Smith BSc,PhD,CEng,FIEE,FIQA,HonFSaRS,MIGasE Tonbridge, Kent UK.
This 7th edition is yet another completely updated and enhanced edition of the leading textbook on this subject (originally published as Reliability and Maintainability in Perspective). It has been established as the definitive guide to practical reliability and integrity assessment, being well known for its uncomplicated approach. Technical terms are explained in a straightforward style and methods are explained with the minimum of mathematics. Major original features of this edition are: * * * * * * Quantifying the uncertainty in reliability prediction A calibrated Common Cause Failure model Failure Rate and Mode Data and a review of Data Sources A radical alternative to Markov modelling Details of cost effective software packages Major Hazards, Integrity of safety-related Systems

CONTENTS (346 pages): PART 1 Parameters and Costs: Chapter 1 History of reliability and safety technology, Chapter 2 Terms and Jargon, Chapter 3 A cost-effective approach. PART 2 Interpreting Failure Rates: Chapter 4 Realistic failure rates, Chapter 5 Interpreting data and demonstrating reliability, Chapter 6 Variable failure rates and probability plotting. PART 3 Predicting Reliability and Risk: Chapter 7 Essential theory, Chapter 8 Methods of modelling, Chapter 9 Quantifying the models, Chapter 10 Risk assessment. PART 4 Achieving Reliability and Maintainability: Chapter 11 Design and assurance, Chapter 12 Design review and test, Chapter 13 Field data collection, Chapter 14 Factors influencing down time, Chapter 15 Predicting and demonstrating down times, Chapter 16 Quantified reliability centred maintenance, Chapter 17 Software quality/reliability. PART 5 Legal, Management & Safety Considerations: Chapter 18 Project management, Chapter 19 Contract clauses and pitfalls, Chapter 20 Product liability and safety legislation, Chapter 21 Major incident legislation, Chapter 21 Safety-related systems, Chapter 22&23 Case Studies. APPENDICES include, A failure rate and mode data base, HAZID checklists, Exercises. ____________________________________________________________________________________ __ To: Phillip Pritchard, Butterworth Heinemann, Linacre House, Jordan Hill, Oxford OX2 8DP, UK Please send me ....... copies of Reliability, Maintainability and Risk (7th ed) by Dr David J Smith ISBN 0 7506 66943. At 39.99 each (+3 P&P). ____________________________Dr David J. Smith BSc,PhD,CEng,FIEE,FIQA,HonFSaRS,MIGasE_______________________

Version 3.2 Nov 2007 OR ORDER DIRECT by credit card from our warehouse on Tel: 01865 314080. Please make cheques payable to Elsevier. Name......................... Address.......................................................................

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____________________________Dr David J. Smith BSc,PhD,CEng,FIEE,FIQA,HonFSaRS,MIGasE_______________________

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BUTTERWORTH - HEINEMANN

FUNCTIONAL SAFETY
2nd EDITION

A STRAIGHTFORWARD GUIDE TO IEC 61508 David J Smith BSc,PhD,CEng,FIEE,FIQA,HonFSaRS,MIGasE Technis, Tonbridge, Kent, UK. Kenneth G L Simpson MPhil,CEng,FIEE,FInstMC,MIGasE Silvertech International.
Following the success of the first edition of this highly topical book, a second edition has been prepared containing numerous additional worked examples and case studies based on the authors up-to-date experience. The book explains the need to specify quantitative safety targets for overall systems, and for their separate protection subsystems. It goes on to describe how to carry out both quantitative and qualitative assessments against those targets. This topic has grown rapidly in importance over the last ten years due to the emergence of International Standard IEC 61508 and related guidance. David (author of Reliability, Maintainability and Risk) and Kenneth have been proactive in the development of IEC 61508 and other documents and both lecture widely on the subject. Major features of this book are: * The explanation of Safety-Integrity Levels (SILs) * Establishing SIL targets * Predicting if those targets can be met quantitatively * Statistical confidence in the results * Addressing the qualitative requirements * Addressing common cause failures * A review of related documents and guidance * WORKED EXAMPLES with answers CONTENTS (in 258 pages):

PART A The concept of safety-integrity: The background to safety targets, Structure and Jargon of IEC 61508.
PART B Requirements of IEC 61508:

Meeting IEC 61508 Parts 1, 2 and 3 and meeting IEC 61511

PART C The quantitative assessment: Reliability modelling, Failure rate and mode data.

PART D Related issues: Comments on Part 6 of IEC 61508, Related guidance documents, Certification.
PART E Examples in the form of Exercises. APPENDICES include, Functional safety capability review sheets, A rigour of assessment schedule, Answers to exercises. ____________________________________________________________________________________ ___ To: Phillip Pritchard, Butterworth Heinemann, Linacre House, Jordan Hill, Oxford OX2 8DP, UK Please send me ....... copies of Functional safety: A straightforward guide to IEC 61508 by Smith & Simpson, ISBN 0 7506 6269 7. At 39.99 each (+3 P&P). OR ORDER DIRECT by credit card from our warehouse on Tel: 01865 474010. Please make cheques payable to Elsevier. ____________________________Dr David J. Smith BSc,PhD,CEng,FIEE,FIQA,HonFSaRS,MIGasE_______________________

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Name......................... Address.......................................................................

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____________________________Dr David J. Smith BSc,PhD,CEng,FIEE,FIQA,HonFSaRS,MIGasE_______________________