Assessment of Significance of Safety Life Cycle Management (SLCM) Approach Using IEC61508 Safety Standard Towards Its Implementation in the Foundry Shop: Case Study of a Pump Manufacturing Industry

Abstract

The authors have designed and developed a framework to implement the safety life cycle management (SLCM) approach for a safety-instrumented system (SIS) aimed at the overall plant safety and analysed the implementation prospects of safety life cycle (SLC) model while discussing the case of foundry operations in a pump manufacturing industry to minimize the occurrence of different induction hazards (hazards associated with the induction furnace). This study has incorporated the SLC model based on IEC 61508 safety standard comprising the three functional phases—analysis, realization and operation phases, for the safer operation of induction furnace. The SIS’s architecture of more diagnostics plus redundancy has to be designed for the increased safety integrity level (SIL) which has been recommended and suggested based on the mathematical interpretations from the study by the computation of safety integrity level (SIL) in conformance with the allocation of safety-instrumented system (SIS) required to overcome the various induction hazards. The increased plant safety, reduced risk and better operational performance, all these can be achieved as the outcome from implementation prospects of safety life cycle management (SLCM) approach. The SLC model being incorporated in this study will gain significant momentum in terms of the overall safety and can benefit the industrial processes and enterprise business as a whole by minimizing the different types of losses in terms of human, material, asset, manufacturing cycle time, etc.