Safety Instrumented Systems

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com
Safety Instrumented Systems (SIS)

and
Safety Life Cycle
Presented in September 2009
By Jennifer L. Bergstrom
Process Engineering Associates, LLC
www.ProcessEngr.com
Safety Instrumented Systems (SIS)

and Safety Life Cycle
Agenda:
zISA standard that defines Safety Life
Cycle
zSafety concepts (including a lot of new
acronyms)
zAspects of the Safety Life Cycle and how
to take it from “cradle” to “grave”
zWays to incorporate SIS into process
design
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ANSI/ISA 84.00.01-2004 for SIS

z ANSI/ISA 84.00.01-2004 (IEC 61511-Mod) -
Application of Safety Instrumented Systems
(SIS) for Process Industries :
{First version in 1996
{Second version approved in 2004 (only addition was
“Grandfather Clause”)
{OSHA recognizes this standard as a RAGAGEP
{Defines all steps that encompass the Safety Life Cycle
{Defines a Safety Instrumented System (SIS)
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Safety Life Cycle

zConcepts (safety acronyms):
{Safety Life Cycle
{Safety Instrumented System (SIS)
{Safety Integrity Level (SIL)
{Safety Instrumented Function (SIF)
{Safety Requirement Specification (SRS)
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Safety Life Cycle

“cradle”
Hazard & Risk
Assessment Design
(PHA, SIL Analysis) (Execute &
Evaluate)
Installation, Commission,
& Validate
Modification
(FAT, SAT, Functional
Proof Test)
Operations
Decommission and
Maintenance
“grave”
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Safety Life Cycle
z Definition: “An engineering process designed to

achieve a risk-based level of safety with
performance criteria that allow versatile
technologies and optimal design solutions.” -exida
z In other words, the cycle is meant to guide a

safety system from the Risk Assessment “cradle”
to the Decommissioning “grave”.
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Why Safety Life Cycle?
zAccidents can and do occur, so in order to

help minimize the frequency and/or
severity…..
zSafety Instrumented Systems and Safety

Life Cycle were designed to minimize risk
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Protection Layers
zSIS is used as a protection layer between

the hazards of the process and the public
(the worse the potential hazard, the more
layers required for prevention/protection)
zExamples:
{BPCS (control system), alarms and operator
response, SIS, physical devices (PSV’s, dikes,
flares, deluges, etc.), and other human
mitigation (emergency response)
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Hazards and Risks in Industry
z Risk – ups and downs –
process risk BPCS

P
alarms
R
O
SIS
C
Risk E
mechanical
S
S
other
tolerable
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SIF and SIL

z Safety Instrumented Function (SIF) is
designed to minimize process risks to a
tolerable level (or ALARP)
z Each SIF is assigned a Safety Integrity Level
(SIL) during SIL analysis - risk assessment
{SIL 0/none – lowest risk
{SIL 1 – 95% of the SIFs
{SIL 2 – 5% of SIFs
{SIL 3 – < 1% (not likely in refineries, but possible in
off-shore platforms or nuclear)
{SIL 4 – highest risk (only seen in nuclear industry)
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Safety Integrity Level (SIL)

z Each SIL rating (increasing in number) must
be that much more reliable and available at
all times (and costs more for upkeep).
z Reliability and availability are achieved by:

{Design – using proper safety components
{Installation – per manufacturer’s guidelines
{Testing – both at initial startup as well as at
specified intervals or after any modification (i.e., via
PSSR)
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Design
z Phase where the SIF/SIS is developed to achieve
the risk reduction that is determined in the PHA or
SIL Analysis (target SIL). Design options can
include:
{Redundancy (initiators, control system, and/or final
elements)
{Type/style of components (transmitter vs. switch or
modulating valve vs. on/off chop valve)
z NOTE: If a SIS already exists, then analysis of the existing

system is done to determine if the target SIL can be achieved
with the current design. (“Grandfather Clause”)
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Design - Type of Failures

z When designing or modifying a SIS, keep in
mind there are two types of failures:
{Safe Failures - “FAIL SAFE”
{Dangerous Failures
z Safe Failures are the desired failure
{Initiated (actual event)
{Spurious (false – undesired but still safe)
z Dangerous failures are not desired
{Inhibited (bypassed)
{Dangerous operation (doesn’t trip when needed)
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Design - Type of Failures
z How do we design for safe failures with minimal

spurious trips?
Safe Dangerous
z Voting Logic
1oo1 good good
1oo2 good best
1oo2D best better
Best blend 2oo2 better good

of both
2oo3 best better
(Source: ISA & Exida)
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Safety Requirement Specification

(SRS)
z The design and verification is compiled into a
document called the Safety Requirement
Specification (SRS)
{Information included:
z Intent of each SIF (the hazard that is mitigated)
z Components of each SIF (sensor, logic solver, final
element)
z Calculations to verify the target (required) SIL can be
achieved
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SIL Verification
z SIL verification involves multiple equations to
determine the achieved SIL.
z Some of the components to verify this
include:
{MTTFS
{PFD
{RRF (inverse of PFD or 1/PFD)
z NOTE: SIL 1 achieves a RRF of 10 to 100

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SIL Verification
z If the required SIL can not be achieved with
the initial design, some options are:
{More frequent proof testing
{Add redundancy (i.e., initiating device, control
system, final element)
{Install “smarter” device (i.e., HART smart transmitter
or transmitter vs. switch or relay, smart control valve
with diagnostics and feedback and position
indication vs. basic control valve)
{Add protection layers (independent)
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General Concepts to Remember in

Design
z Two ways to achieve lower MTTFS (PFD) or
higher RRF to achieve the target SIL:
{Diagnostics, diagnostics, diagnostics,…
{Redundancy
z Instrumentation with diagnostics is the key!

{Feedback information can tell you the condition of
the instrument and whether it is “ill” and about to fail
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General Concepts to Remember in

Design
z Transmitter is better than a switch or relay
z If using switch, solenoid, or relay (anything on/off or
discrete), verify that it is normally energized during
operation (fail safe)
z Use dedicated wiring to each device (as much as
possible)
z Minimize common cause failures (i.e., common
wires, instrument taps – including bridles, or same
controller or I/O card)
z Mechanical devices are the weakest link in the SIF.
They can stick if not moved periodically (i.e., PSVs,
valves, switches)
{ To remedy this issue: install double blocks or modulating
valves that can be partially stroked
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Functional Proof Tests

z Proof Tests must be performed at the frequency
stated in the SRS to continue the reliability of the
SIF.
z It should include the following information:
{ Test procedure
z Test all bypasses, all individual initiators, and final
elements
z Results of all steps of the procedure
z Verification that process has been restored to normal
operation
{ Date of test and all personnel performing the test
{ Control logic – version # (if available)
{ Results of entire test and any abnormalities found
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Final Review
z Safety Life Cycle
{ Guidelines for a safety system from the Risk Assessment
“cradle” to the Decommissioning “grave”.
z SRS
{ It is only a portion of the Safety Life Cycle, but documents and
verifies the SIF design
z Employer must also fulfill the SRS timelines as
determined in the SRS to the keep the SIF reliable
and available to reduce risk.
{ Functional Proof Test – at a specified interval
{ Mission Time – replacement interval
{ Document any modifications to SIS or protection layers
(MOC)

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What is the purpose of the Safety Life Cycle?

What is the purpose of the Safety Life Cycle?

What are some important concepts defined in the Safety Life Cycle?

What are some important concepts defined in the Safety Life Cycle?

www.ProcessEngr.

Safety Instrumented Systems (SIS)

Safety Instrumented Systems (SIS)

ANSI/ISA 84.00.01-2004 for SIS

Safety Life Cycle

Safety Life Cycle

Safety Life Cycle

z Definition: “An engineering process designed to

z In other words, the cycle is meant to guide a

Why Safety Life Cycle?

zAccidents can and do occur, so in order to

zSafety Instrumented Systems and Safety

zSIS is used as a protection layer between

Hazards and Risks in Industry

z Risk – ups and downs –

process risk BPCS

SIF and SIL

Safety Integrity Level (SIL)

z Reliability and availability are achieved by:

z NOTE: If a SIS already exists, then analysis of the existing

Design - Type of Failures

Design - Type of Failures

z How do we design for safe failures with minimal

Best blend 2oo2 better good

Safety Requirement Specification

z NOTE: SIL 1 achieves a RRF of 10 to 100

General Concepts to Remember in

z Instrumentation with diagnostics is the key!

General Concepts to Remember in

Functional Proof Tests

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