SIL-4 Gap and Safe-State Holes in EDG Specification

System

Red team adversarial review of the {{entity:Emergency Diesel Generator for a UK Nuclear Licensed Site}} decomposition. At entry: 226 requirements (66 SUB, 20 IFC, 16 SYS, 7 STK, 109 VER, 7 ARC), 306 trace links, 8 diagrams, 42 classified entities, 10 registered hazards. 35 lint findings at medium severity. The system has completed validation — this session stress-tests the specification before it is marked production-grade.

Adversarial Findings

SIL Gap (1 finding). Hazard H-007 (Common Cause Failure of both EDGs) is rated SIL-4 in the hazard register, but no requirement in the project carries a sil-4 tag. The highest SIL allocation on any requirement is SIL-3. {{sys:SYS-REQ-011}} addresses CCF architecturally but is tagged sil-3. IEC 61508 (Functional safety of E/E/PE safety-related systems) requires that a SIL-4 hazard be mitigated by requirements at SIL-4 or by a demonstrated architectural decomposition proving equivalent reliability — neither is present.

Missing Safe States (2 findings). 5/10 hazards lack safe-state tagged SUB requirements: H-002 (loss of output during operation), H-007 (CCF), H-008 (seismic damage), H-009 (spurious start/trip), H-010 (cyber attack). Tagged {{sys:SYS-REQ-006}} and {{sys:SYS-REQ-016}}.

Untestable Requirements (3 findings). {{sys:SYS-REQ-005}} specifies PFD ≤ 1×10⁻³ but sets verification to Inspection — PFD is a probabilistic calculation requiring Analysis (fault tree per IEC 61508 Part 6), not document inspection. {{sub:SUB-REQ-027}} and {{sub:SUB-REQ-067}} are SIL-3 requirements verified by Inspection; SIL-3 functions under IEC 61508 require functional testing or rigorous analysis, not inspection alone.

Missing Failure Modes (4 findings). {{entity:cooling system}} has only 4 SUB requirements (vs 9.4 average), with no failure-mode requirement for the {{entity:Jacket Water Pump}} ({{sub:SUB-REQ-037}}) or {{entity:Radiator and Fan Assembly}} ({{sub:SUB-REQ-038}}). {{entity:alternator-subsystem}} has 5 SUB requirements with no failure-mode handling for AVR ({{sub:SUB-REQ-046}}) or brushless excitation ({{sub:SUB-REQ-049}}). Both subsystems serve safety functions.

Implausible Values (2 findings). 500ms timing appears across 16 requirements spanning overspeed trip, alarm annunciation, Modbus polling, relay response, and LOOP detection — functions with fundamentally different timing constraints. {{sub:SUB-REQ-034}} and {{sub:SUB-REQ-035}} flagged as likely inheriting a default rather than independently derived timing budgets.

Vague Interface (1 finding). {{ifc:IFC-REQ-019}} (crankshaft-to-generator coupling) specifies mechanical parameters but omits dynamic alignment tolerance, vibration transmissibility, and coupling service life — critical for a machine running 168-hour endurance cycles.

Proportion. Requirement density per subsystem ranges from 4 ({{entity:cooling system}}) to 12 ({{entity:diesel engine subsystem}}). Lint identified 7/15 {{trait:System-Essential}} components without redundancy/failover requirements. 18 STK/SYS concepts have no downstream decomposition.

flowchart TB
  n0["Emergency Diesel Generator<br>for a UK Nuclear Licensed Site"]
  n1["DC Battery System"]
  n2["Emergency AC Bus"]
  n3["Plant Protection System"]
  n4["Main Control Room"]
  n5["National Grid"]
  n6["Ultimate Heat Sink"]
  n7["Fuel Supply"]
  n3 -->|Start/stop command| n0
  n1 -->|110V DC control power| n0
  n0 -->|6.6kV Class 1E power| n2
  n0 -->|Status and alarms| n4
  n5 -->|LOOP detection signal| n0
  n7 -->|Diesel fuel| n0
  n6 -->|Cooling water| n0

Flagged Requirements

RefCategoryIssue
{{sys:SYS-REQ-011}}rt-sil-gapH-007 is SIL-4 but requirement is SIL-3; no SIL-4 allocation exists
{{sys:SYS-REQ-005}}rt-untestablePFD ≤ 1×10⁻³ verified by Inspection; requires Analysis per IEC 61508
{{sys:SYS-REQ-006}}rt-missing-safe-stateSeismic hazard H-008 has no safe-state SUB requirement
{{sys:SYS-REQ-016}}rt-missing-safe-stateCyber hazard H-010 has no safe-state SUB requirement
{{sub:SUB-REQ-027}}rt-untestableSIL-3 seismic qualification verified by Inspection only
{{sub:SUB-REQ-067}}rt-untestableSIL-3 LOTO reinstatement verified by Inspection only
{{sub:SUB-REQ-037}}rt-missing-failure-modeJacket Water Pump has no pump failure/degradation requirement
{{sub:SUB-REQ-038}}rt-missing-failure-modeRadiator assembly has no fan failure or fouling requirement
{{sub:SUB-REQ-046}}rt-missing-failure-modeAVR has no voltage regulator failure/fallback requirement
{{sub:SUB-REQ-049}}rt-missing-failure-modeBrushless excitation has no exciter failure requirement
{{sub:SUB-REQ-034}}rt-implausible-value500ms Modbus timeout matches unrelated subsystem timing
{{sub:SUB-REQ-035}}rt-implausible-value500ms alarm latency identical to safety trip timing
{{ifc:IFC-REQ-019}}rt-vague-interfaceMechanical coupling lacks alignment tolerance and service life

Domain Analogs Checked

AnalogSourceGaps Surfaced
{{entity:Safety Interlock and Trip System}}Factory corpusConfirms need for watchdog and self-test; present in spec
{{entity:Nuclear Reactor Protection System}}Factory corpusSuggests voting architecture for trip channels; partially present (2oo2 on start, absent on trip)
{{entity:Sequential Events Controller}}Factory corpusSuggests time-stamped event recording for post-incident analysis; absent from EDG requirements
{{entity:Diesel Fuel Supply Infrastructure}}Factory corpusSuggests fuel quality monitoring (water, particulate, microbial); only particulate filtration present

Recommendations

  1. Resolve SIL-4 gap. Either create a SIL-4 requirement for H-007 CCF mitigation with architectural redundancy justification, or document in ARC why SIL-3 allocation per train is sufficient via IEC 61508 Part 6 architectural decomposition.
  2. Add safe-state requirements for H-002, H-007, H-008, H-009, H-010. Each hazard safe state is named in the register but has no implementing SUB requirement.
  3. Fix verification methods on SYS-REQ-005 (change to Analysis), SUB-REQ-027 and SUB-REQ-067 (add Test or Analysis alongside Inspection).
  4. Expand cooling system requirements: pump failure detection, fan motor failure, coolant leak detection, fouled radiator degradation.
  5. Expand alternator subsystem requirements: AVR failure fallback, exciter fault detection, bearing temperature trending.
  6. Justify or differentiate 500ms timing values — independent derivation for alarm annunciation vs safety trip vs communications polling.
  7. Add event sequence recording requirement (analog gap from Sequential Events Controller).
  8. Add fuel quality monitoring beyond particulate filtration (water content, microbial growth per BS EN 590).

Verdict

Informational. 13 findings: 1 rt-sil-gap (high), 3 rt-untestable (medium), 4 rt-missing-failure-mode (medium), 2 rt-missing-safe-state (high), 2 rt-implausible-value (low), 1 rt-vague-interface (low). The SIL-4 gap and missing safe-state coverage are the highest-priority items — they represent holes in the safety argument that would be identified during regulatory review. The specification is otherwise well-constructed with strong quantification, good EARS compliance, and thorough verification coverage.

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