Safety Instrumented Systems
ANGELA E. SUMMERS, PH.D., P.E. SIS-TECH Solutions, LLC
Were Proven-in-Use.
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Terminology
Critical Control Systems Safety Shutdown Systems Protective Instrumented Systems Equipment Protection Systems Emergency Shutdown Systems Safety Critical Systems Interlocks Safety Instrumented Systems
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What is a Safety Instrumented System (SIS)?
An SIS is designed to:
respond to conditions in the plant which may be hazardous in themselves or, if no action was taken, could eventually give rise to a hazard, and to respond to these conditions by taking defined actions that either prevent the hazard or mitigate the hazard consequences.
Input ---- Logic Solver ---- Output
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Examples of Safety Instrumented Systems
High fuel gas pressure furnace initiates shutdown of main fuel gas valves. High reactor temperature initiates fail open action of coolant valve. High column pressure initiates fail open action of pressure vent valve.
OSHA
&
EPA
Process Safety Management
SIF included here
Emergency Shutdown Systems, Control, Relief Systems
Written Internal Guidelines
Mentor/Engineering Practices
Industry Codes & Standards
GOOD ENGINEERING PRACTICE
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Standards Bodies that Define Good Engineering Practice for Safety Instrumented Systems
ISA, Instrumentation Systems and Automation Society IEC, International Electrotechnical Commission
Other standards and guidelines must be integrated with SIS standards!
NFPA API ISA 84.01-2003
IEC 61508
ASME
IEC 61511
Boiler Codes
ISO
AICHE Books
Safety Instrumented System Standards
IEC 61508 - Functional Safety: Safety Related Systems Current version released 1999 Under revision for next release 2005
IEC 61511 - Functional Safety: Safety Instrumented Systems for the Process Industry Sector Published 2003 ISA 84.01-2003 - Functional Safety: Safety Instrumented Systems for the Process Industry Sector Identical to IEC 61511 with inclusion of grandfather clause To be published October 2003
Planning Front End Engineering
Management of Change
Safety Lifecycle
Engineering Design
Operations & Maintenance
Commissioning
Manage risk - People
Identify role of individual or departments
Who is assigned to project? What are their roles?
Document competency of individuals and departments
Does anyone need more training? Who will mentor inexperienced engineers? Who will review and approve?
This is good project management.
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Manage risk Procedures
Define when the following will take place:
Verifications, Audits, and Validation.
Require procedures for evaluating the performance of the SIS after it has been installed
Performance audits and Tracking failures rates.
This is good quality control.
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Assess risk and mitigate it
Will talk about the how to later The assessment results in the assignment of Safety Integrity Level
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Safety Integrity Level
SIL PFDavg Risk Reduction Availability (%)
10-4 to 10-5
10,000 to 100,000
99.99 to 99.999
10-3 to 10-4
1,000 to 10,000
99.9 to 99.99
10-2 to 10-3
100 to 1,000
99 to 99.9
10-1 to 10-2
10 to 100
90 to 99
Lets talk about Risk. What is your wager? How many times do you place the wager each year? What are your odds of losing your wager?
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Design SIF
Justify selection of devices Document the safety requirements specification Design SIFs to achieve Safety Integrity Level.
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Prove it
Verify
Safety Integrity Level Fault tolerance
Commissioning
Install SIFs per design documents
Functional safety assessment
Make sure all documents are in place and all hazards analysis items are addressed.
Validation
Test SIFs to ensure that they have desired functionality
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Maintain it
Operation, maintenance and testing
Use diagnostics and testing to maintain performance Create and maintain procedure to support these activities Train personnel on procedures
Management of change
Monitor changes to SIS that might affect SIL
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Audit it
Includes design and procedures Define frequency of audits Determine the degree of independence of auditing activity Document audit Define follow-up activities
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Planning Front End Engineering
Management of Change
Safety Lifecycle
Engineering Design
Operations & Maintenance
Commissioning
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