Framework for Life Cycle Management of Safety Instrumented System (SIS) in Manufacturing Facilities of Large Corporation

The risks on safety of human life in manufacturing facility, environment and asset are mitigated by use of Safety Instrumented System (SIS). Usually, many SIS are installed in manufacturing facilities that are using continuous process or machinery.The maintenance cost and risk mitigation are of contradicting in nature. The budget decision for establishment and maintenance of SIS has become critical after the experience of many accidents, in oil and gas and other production facilities, during recent years. IEC 61508 is a standard of practice for life cycle management of safety system is in various public domains. There are other standards available in assets management such as ISO 55000, etc.In this paper, a feasible methodology is presented for, life cycle management of SIS assets. This framework supports the decisions on maintenance, replacement, reliability and Asset Performance measurement. The framework, workflow, procedures of SIS asset management, risk assessment, Safety Integrity Level (SIL), proof testing, Preventive Maintenance (PM), recommendation, execution of PM, etc. are disseminated. Two specific industrial examples are also presented. This framework can be scaled up for entire manufacturing facilities of the corporation in all geographical locations.