Automate More Than Your Processes, Automate Your Procedures

Problem / Scope

Safety Instrumented System (SIS) testing is a US regulatory requirement, but the quality, coverage, repeatability, and auditability vary widely from site to site. Often, schedule and budget concerns or staffing limitations pressure owners to trim tests down, focusing on speed of execution rather than quality validation. In many cases, even a quality test when done quickly can be hard to audit.

Koch Ag & Energy Solutions (KAES), in partnership with ProLytX, has moved towards a better solution. The key to this solution is adopting a segmented testing approach and combining it with automated validation software to dramatically reduce plant downtime and cost while improving their facilities' overall quality of testing and safety.

Methodology

IEC61511 allows for segmented testing (testing in parts). Using this methodology, all SIS logic can be validated outside of a Turnaround or maintenance window and coupled with loop tests and field inspection to provide full coverage. KAES and ProLytX will present how a combination of automated testing software and segmented testing methodology can reduce downtime and manpower while also improving test coverage and documentation.

Results

Data from multiple sites (100+) will be shown that document plant savings and testing discoveries. Critical path reductions typically land between 0.5 to 5 days with immediate ROI on procedure development. The presentation will cover sample test failures, logistics, comparison of manual and automated methodology (pros and cons), and suggested modifications to site testing and Management of Change (MOC) requirements.

Implications

Reduce human errors and execution time through automation and segmented testing.

Improve testing quality and coverage with extensive procedures.

Improve safety by finding hidden failures and testing abnormal conditions.

Background

Brian Bailey, CFSE – Director of Functional Safety @ ProLytX - ~17 years in Automation and SIS Implementation.

David Wicker – Director of Technology @ ProLytX - ~17 years in Automation and SIS Implementation.

Chris Reeves – Functional Safety Manager / Reliability SME - ~30 years in Instrumentation / Automation*

*Koch Ag & Energy Solutions details to be vetted by legal prior to submittal. Do not share abstract details outside of the organization until the paper is approved.