SIS Design and Engineering: A Comprehensive Approach
Abstract
Safety Instrumented Systems (SIS) are essential in managing and mitigating risks in high-
stakes industrial environments. Designing and engineering an SIS requires a detailed,
structured approach to ensure that the system meets functional safety standards and performs
reliably under hazardous conditions. This essay covers a step-by-step SIS development plan,
functional testing procedures, document preparation and information flow, change
management, and a comprehensive SIS design checklist.
1. Step-by-Step Safety Instrumented System Development Plan
The development of an SIS follows a systematic plan, involving several stages from initial
design to commissioning and maintenance. Each stage ensures that the SIS meets required
Safety Integrity Levels (SILs) and effectively addresses identified risks.
Step 1: Hazard and Risk Assessment
• Objective: Identify hazards and assess associated risks.
• Activities: Conduct studies like HAZOP (Hazard and Operability) and LOPA (Layers
of Protection Analysis) to identify potential hazardous events and evaluate risk levels.
• Outcome: Define safety requirements for Safety Instrumented Functions (SIFs) and
assign preliminary SIL levels.
Step 2: Safety Requirements Specification (SRS)
• Objective: Document the functional and performance requirements of the SIS.
• Activities: Create an SRS detailing required actions, response times, reliability
targets, and environmental requirements for each SIF.
• Outcome: A finalized SRS document that serves as the foundation for the SIS design
and implementation.
Step 3: SIS Design and Engineering
• Objective: Design the SIS to meet the SRS requirements and achieve the desired SIL.
• Activities: Select appropriate sensors, logic solvers, and final elements; specify
redundancy and voting schemes; design fail-safe configurations and conduct
reliability analysis.
• Outcome: A design that meets functional safety standards (IEC 61508 and IEC
61511) and includes adequate redundancy to reduce risks.
Step 4: Implementation and Installation
• Objective: Physically install the SIS according to the design specifications.
• Activities: Install and wire SIS components, configure logic solvers, and implement
any necessary custom programming.
• Outcome: A functional SIS that is ready for commissioning and testing.
Step 5: Commissioning and Validation
• Objective: Validate that the SIS performs as designed and meets all specified safety
requirements.
• Activities: Perform functional testing, proof testing, and validation checks, including
field testing for sensors and actuators.
• Outcome: A validated SIS that is ready for operation, with documented test results.
Step 6: Operation and Maintenance
• Objective: Ensure ongoing reliability and functionality of the SIS.
• Activities: Regular proof testing, calibration, preventive maintenance, and monitoring
of diagnostic feedback.
• Outcome: A maintained and tested SIS that continues to perform its safety functions
over time.
Step 7: Decommissioning and Replacement
• Objective: Safely retire the SIS or replace aging components.
• Activities: Perform decommissioning activities, update documentation, and integrate
new systems if necessary.
• Outcome: Properly documented and safely decommissioned system, with updated
SIS records for the new installation.
2. SIS Functional Testing Procedures
Functional testing of an SIS verifies that each component and function performs as intended,
ensuring safety and reliability in hazardous conditions. Proper functional testing includes
several important steps:
1. Pre-Testing Preparation: Confirm that test procedures are well-defined, risks are
minimized, and all personnel involved are aware of the test’s scope and objectives.
2. Testing Individual Components: Each component (sensors, logic solvers, final
elements) is tested independently to verify that it operates within specifications.
3. Testing the Complete SIF: Each SIF is tested end-to-end, confirming that sensors
detect a hazardous condition, the logic solver processes the input correctly, and the
final element (e.g., valve) responds appropriately.
4. Proof Testing: Proof testing checks that the SIS remains within its target PFD
(Probability of Failure on Demand) by identifying and correcting any undetected
faults.
5. Dynamic Testing (for Programmable Systems): For PLC- or microprocessor-based
systems, dynamic testing is conducted to ensure software and logic function as
intended under real-world conditions.
6. Final Functional Test and Validation: Conduct a final test of the entire SIS in an
operational environment to validate system reliability and compliance with the Safety
Requirements Specification.
3. Information Flow and Preparation of Documents
Effective documentation and information flow are critical in SIS design and engineering. The
preparation of detailed, organized documentation ensures clear communication, facilitates
future maintenance, and supports regulatory compliance.
Key Documents in SIS Design and Implementation
1. Safety Requirements Specification (SRS): Specifies functional, performance, and
SIL requirements for each SIF, serving as a reference throughout the lifecycle.
2. SIS Design Documentation: Details the SIS architecture, component specifications,
and redundancy requirements, including wiring diagrams, P&IDs, and logic diagrams.
3. Functional Testing Procedures: Outlines the steps for functional testing, proof
testing, and validation, including expected outcomes.
4. Installation and Commissioning Records: Provides installation details,
configuration settings, and records of commissioning tests, demonstrating that the SIS
was installed as designed.
5. Operational and Maintenance Manuals: Guides regular testing, calibration, and
maintenance to ensure long-term reliability and availability.
6. Change Management Records: Documents any modifications or adjustments made
to the SIS, including rationale, testing results, and approval records.
Information Flow
Effective information flow involves clear communication between all stakeholders, including
engineers, operators, maintenance personnel, and safety managers. Each phase of the SIS
lifecycle should involve a review and handoff of documentation to ensure that information is
correctly interpreted and implemented.
4. Managing Existing and Future Changes to an SIS
Change management is essential for maintaining the reliability and safety integrity of an SIS
throughout its lifecycle. Changes in process requirements, system upgrades, or component
replacements can impact the SIS’s performance and SIL.
Types of Changes and Their Management
1. Modifications to Safety Functions: If a SIF requires modification, the impact on the
overall SIS must be assessed. Modifications may require re-evaluation of the SIL,
updates to the SRS, and functional testing.
2. Upgrading Components: When replacing sensors, actuators, or logic solvers, the
new components must meet or exceed the reliability of the original components.
Testing is necessary to ensure compatibility and functionality.
3. Software Updates: Software changes in PLCs or microprocessor systems require
testing and validation to prevent the introduction of systematic errors.
4. Documentation Updates: Every change must be documented, including the reason
for the change, affected components, testing results, and approvals. This
documentation helps maintain an accurate record of the SIS configuration.
5. Stakeholder Approvals: Any change to the SIS should be approved by relevant
stakeholders, including safety engineers and management, to ensure it aligns with
safety objectives.
5. Review of an SIS Design Checklist
A comprehensive checklist for reviewing an SIS design helps ensure that all critical factors
have been considered and addressed during the development process. Below is a sample
checklist for SIS design review:
Checklist Item Description
Hazard Analysis and Risk
Ensure all hazards are identified, risks assessed, and SILs
Assessment assigned according to the SRS.
Safety Requirements Verify that the SRS includes complete, clear specifications for
Specification (SRS) each SIF, with defined SILs and actions.
Confirm that sensors, logic solvers, and final elements meet
Component Selection
SIL requirements and environmental conditions.
Redundancy and Voting Verify that redundancy and voting schemes are appropriate for
Schemes achieving desired SIL and minimizing nuisance trips.
Ensure all components are designed to default to a safe state in
Fail-Safe Design
case of failure.
Functional Testing Confirm that functional and proof testing procedures are
Procedures documented, including expected results.
Review diagnostic coverage levels and periodic testing to
Diagnostic Coverage
identify potential faults early.
Documentation and Ensure all design, installation, testing, and maintenance
Information Flow documentation is complete and accessible.
Review the change management process, ensuring that
Change Management Plan
modifications are documented, approved, and tested.
Compliance with Verify that the design meets IEC 61508, IEC 61511, and other
Standards relevant standards and regulatory requirements.
This checklist supports thorough review, reducing the risk of omissions and ensuring that the
SIS design meets safety and reliability objectives.
