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SIS life-cycle: Overview of typical activities and documentsThis document provides an overview of typical Functional Safety activities and documents based on IEC 61511:2017. The overview can be used to manage Functional Safety projects.Set up functional safety management planstatusResponsibleProject/plant manager?ObjectiveTo manage the development, realisation and maintenance of a SIS?BasisProject definition, basis for design, Process Flow Schemes, P&IDs?Activities:PersonnelDetermine which departments / personnel need to be involved during the relevant SIS lifecycle phasesDetermine competence requirements for the key personnel Check competence of key personnelPlanningDetermine the applicable SIS life-cycle phases and the relevant activities and documents (this overview may help)Make a realistic planning when activities should be performedDevelopment processA verification system should be set up in order to guarantee the quality of activities and documentsAll documents shall be checked and approvedDeliverablesFunctional safety management planLife-cycle planningReference: IEC 61511 clauses 5, 6 and 7 Hazard and risk assessmentstatusResponsibleProcess safety engineer / Process engineerObjectiveTo identify all process hazards and to determine associated risksBasisP&IDs and other relevant conceptual documentsActivitiesDetermine scope of workOrganise HAZOP and risk assessment brainstorm sessionsDetermine team composition for the brainstorm sessionsCheck if the proposed HAZOP chairman is well-experiencedEnsure that appropriate HAZOP and risk assessment methodologies will be usedDeliverableHAZOP and Risk Assessment reportReference: IEC 61511 clause 8 Allocation of safety functions to protection layersstatusResponsibleProcess engineer / Process safety engineerObjectiveTo select appropriate risk reducing measuresBasisHAZOP and Risk Assessment report and P&IDsActivitiesInherently safe design is preferredMechanical safeguards may be selected as well as instrumental safeguards or other means of risk reductionDetermine the instrumental safeguards (SIFs) and associated SILDeliverableAllocation report (might be an addendum of the HAZOP+RA report)Reference: IEC 61511 clause 9Safety Requirements Specifications (SRS)statusResponsibleProcess safety engineer ObjectiveTo specify the SIFs to be able to design these SIFs. BasisAllocation report, HAZOP and risk assessment report, P&IDsActivitiesDefine all SIFs; sensors, logic solver function, final elements, overrides (if any), reset functions, Process Safety Times, if valves should be tight shut-off, required risk reduction factor (or PFD)A SRS is a multidisciplinary document. It must be approved by the involved disciplinesMake Cause & Effect diagrams to be used by the FLD designers, during verification / validation and OperationsDeliverablesDetailed SRSsCause & Effects diagram(s)Reference: IEC 61511 clause 10Functional Safety Assessment stage 1 (FSA 1)statusResponsibleIndependent competent engineerObjective To ensure that the SIS life-cycle activities up to and including the SRS have been performed correctlyNote: The SRS is a critical document, it will be used for the design of the SIFs and it will be used as basis for the verification / validationBasisSRSs, P&IDs, HAZOP and risk assessment report, allocation reportActivitiesVerification if involved personnel are competentVerification if the SRSs are correct and completeVerification if the Cause & Effects diagrams are correctDeliverableFSA 1 reportReference: IEC 61511 clause 5.2.6.1 Design of the SISstatusResponsibleInstrumentation engineerObjectiveTo develop the detailed design of the SISBasisSRS and P&IDsNarratives, company / project terms of reference, FSA-1 reportActivitiesSpecify all instruments, systems and auxiliaries to be purchasedDesign the wiring / cabling, power supply, instr. air provisions, etc.Design the human-machine interfacesDevelop the Application ProgramPerform a SIS security risk assessmentPerform auditsVerify if the SIF design comply with IEC 61511 / 61508Typical design deliverablesSpecification / requisition of the SIS logic solverSIS Instruments data sheetsSpecification / requisition of the SIS instrumentsSIS auxiliary cabinets configurationSpecification / requisition of the SIS auxiliary cabinetsSpecification / requisitions of SIS valves / actuators / solenoid valvesSIS Functional Logic DiagramsSIS Application ProgramSIS Application Program verification reportHuman-machine interfaces for Operations and MaintenanceWiring diagramsLay out drawingsSIS Loop diagramsSupporting provisions, tracing and insulationTypical other deliverablesSIS security risk assessment reportSIL design verification reportVendors audit reports. Reviews to be performed to ensure that the vendors functional safety management systems are in placeSIFs test proceduresLoop test proceduresFAT proceduresSIS maintenance management databaseSIS installation planSIS validation proceduresEvaluation forms of suppliers quotations / documents / safety manualsSpare parts listReference: IEC 61511 clauses 11 and 12 Factory Acceptance Tests (FATs)statusResponsibleInstrumentation engineerObjectiveTo verify if systems / cabinets are realised correctlyBasisSRS and P&IDs, FAT procedures, Design documents, relevant specification / requisition, vendor documents (e.g. safety manuals), vendor audit reportActivitiesOrganise FATs, determine participants, vendor to make test provisionsPerform FATsVerify the Application Program in the safety PLCDeliverablesFAT reportsReference: IEC 61511 clause 13 Functional Safety Assessment stage 2 (FSA 2)statusResponsibleCompetent independent engineerObjective To ensure that the activities of the SIS life-cycle phases ‘Design of the SIS’ and ‘FATs’ have been performed correctlyBasisSRS and P&IDs, Design documents, FAT reports, specifications / requisitions and vendor documentsActivitiesVerification if involved personnel are competentVerification if the recommendations of FSA-1 are implementedVerification of design documentsVerification of the Application Program documentsVerification if the FAT recommendations are implementedDeliverableFSA 2 reportReference: IEC 61511 clause 5.2.6.1 SIS installation and commissioningstatusResponsibleInstrumentation engineerObjectivesTo realise and pre-test the SISBasisInstallation plan, design documents, vendor documents, FAT reports, FSA 2 report, Loop test proceduresActivitiesInstallation of the SIS Commissioning of the SIS so that it is ready for final system validation.DeliverablesAs built marked-up design documentsRecords of the commissioning of the SISReference: IEC 61511 clause 14 SIS safety validationstatusResponsibleInstrumentation engineerObjectiveTo validate that the installed and commissioned SIS and its associated SIFs achieve the requirements as stated in the SRS BasisSRS’s, proof test procedures, validation procedures, design documents, vendor documents, FAT reportsActivitiesPerform inspections and testsDeliverablesValidation reportUpdate of the SIS maintenance management database with the test resultsReference: IEC 61511 clause 15 Functional Safety Assessment 3 (FSA 3) – SIL Field validationstatusResponsibleCompetent independent engineerObjectiveTo ensure that the activities of the SIS life-cycle phases ‘SIS installation and Commissioning’ and ‘SIS safety validation’ have been performed correctlyBasisP&ID’s, SRS, design documents, vendor documents, validation procedures & validation results, proof test procedures and proof test resultsActivitiesVerification if involved personnel are competentVerification if the proof tests / validations procedures are adequateVerification if all tests / validations are performed, evaluation of the test resultsVisual inspection of SIS instrumentsDeliverableFSA 3 reportReference: IEC 61511 clause 5.2.6.1 Operation and maintenancestatusResponsibleProject / Operations / Maintenance managersObjectiveTo maintain the SIL of each SIF, to operate and maintain the SIS in a way that sustains the required safety functionsBasisValidated SIS and Up-to-date SIS documentsActivitiesImplement the recommendations of FSA 3Take care of awareness and competence of personnelOrganise operators training Organise maintenance training Perform periodical proof tests and visual inspectionsKeep the maintenance management database up-to-dateUse approved procedures for bypassing elements of the SIF when neededPerform preventive and breakdown maintenance of the SIS, e.g. periodical overhaul of valves by valve vendor and calibration of sensorsTake care of adequate spare parts and service contracts Reference: IEC 61511 clause 16AbbreviationsFATFactory Acceptance TestFLDFunctional Logic DiagramsFSAFunctional Safety AssessmentHAZOPHAZARD & OperabilityPFDAverage Probability of Failure on DemandPLCProgrammable Logic ControllerP&IDPiping & Instrumentation DiagramRARisk AssessmentSIFSafety Instrumented FunctionSILSafety Integrity LevelSISSafety Instrumented SystemSRSSafety Requirements SpecificationReference: IEC 61511 clause 3 ................
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