Who has a site management procedure for plant safety instrumented systems?

You may refer to this system ------------------------------------------- **Guiding Opinions of the State Administration of Work Safety on Strengthening the Management of Safety Instrumented Systems in the Chemical Industry, Document No. An Jian Zong Guan San [2014] 116** To the work safety supervision bureaus of all provinces, autonomous regions, municipalities directly under the Central Government, and the Xinjiang Production and Construction Corps, as well as relevant central state-owned enterprises: In order to strengthen the management of safety instrumented systems in the chemical industry and prevent and reduce accidents involving hazardous chemicals, the following guiding opinions are put forward: I. Fully recognize the importance of strengthening the management of safety instrumented systems in the chemical industry (1) Safety instrumented systems (SIS) include safety interlock systems, emergency shutdown systems, and detection and protection systems for toxic and harmful gases, flammable gases, and fires. The Safety Instrumented System operates independently of the process control system (such as a distributed control system). Under normal operating conditions, it remains dormant or inactive. However, in the event that any situation arises within the production equipment or facilities that could potentially lead to a safety incident, it can activate instantly and accurately, thereby safely shutting down the production process or automatically bringing it into a predetermined safe state. It must therefore possess a high level of reliability (i.e., functional safety), along with proper maintenance and management procedures. Should the Safety Instrumented System fail, it often results in serious safety accidents. In recent years, most major chemical (hazardous chemicals) accidents occurring in developed countries have been associated with malfunctions or improper configuration of such systems. Based on the consequences and risks resulting from the failure of safety instrument functions, these functions are classified into different safety integrity levels (SIL1-4, with level 4 being the highest). Safety instrumented loops of different levels have different technical requirements regarding design, manufacturing, installation and commissioning, as well as operation and maintenance. At present, in China’s safety instrumented systems and related safety protection measures, various issues exist across all stages of their life cycle – including design, installation, operation, and maintenance – such as inadequate hazard and risk analysis, improper design choices, unreasonable redundant fault-tolerance structures, the lack of defined inspection and testing schedules, and preventive maintenance strategies that are not effective enough. It is therefore urgent to strengthen the regulation of safety instrumented system management. As China’s chemical processing facilities and hazardous chemical storage installations become larger in scale and the level of automation in production processes continues to improve, it is extremely urgent and necessary to strengthen and standardize the management of safety instrumented systems. II. Strengthening the foundational work for the management of chemical process safety instrumented systems (II) Accelerate the training of technical and managerial personnel skilled in functional safety related to safety instrumented systems. Chemical engineering design and construction firms, as well as entities involved in the production and storage of hazardous chemicals, should organize specialized training on safety instruments for relevant personnel, as well as engineering and technical staff working on processes and instrumentation. This training should aim to spread knowledge related to functional safety and to familiarize them with relevant standards and regulations. Targeted training should be provided to design, installation and commissioning, as well as operation and maintenance personnel at various stages of the safety instrument system’s lifecycle, so that they can master relevant professional skills such as safety instrument systems, risk analysis and control, and risk mitigation. Each chemical engineering design firm should take about a year to build a team of technical experts capable of handling the functional safety design of safety instrumented systems. Chemical enterprises operating production facilities involving the “two key areas and one major hazard” (namely, hazardous chemicals under key supervision, hazardous chemical processes under key supervision, and major hazards related to hazardous chemicals), as well as units storing hazardous chemicals, must accelerate their efforts in talent cultivation. They should train a group of engineering technicians who possess professional technical capabilities and have a thorough understanding of relevant standards and regulations, so as to meet the needs of implementing and strengthening functional safety management of chemical safety instrument systems. (III) Further improve the technical standards and certification system for chemical process safety instrument systems. Accelerate the formulation and revision of the technical standard system for chemical process safety instrumented systems. To organize research and develop a technical standard system for functional safety in China’s chemical industry, relevant departments and organizations need to establish work plans to formulate functional safety-related technical standards and application guidelines that are suited to the current safety development situation of enterprises in this industry. Promote the establishment and improvement of a functional safety certification system and mechanism suited to China’s national conditions. In accordance with “Functional Safety of Electrical/Electronic/Programmable Electronic Safety-Related Systems” (GB/T 20438) and “Functional Safety of Safety Instrumented Systems in the Process Industry” (GB/T 21109), a functional safety certification service system for relevant personnel, products, and organizations shall be gradually established. III. Further strengthen the management of the entire lifecycle of safety instrumented systems (IV) Before designing a safety instrumented system, it is necessary to clarify the process safety requirements, design intent, and basis for the system. Through process hazard analysis, it is necessary to fully identify hazards and hazardous events, scientifically determine the required safety instrument functions, and assess safety risks in accordance with **laws, regulations, and standards to establish the necessary risk reduction requirements. Prepare the technical document for the safety requirements of the safety instrumented system in accordance with the functional and integrity requirements of all safety instrument functions. (5) Standardize the design of chemical safety instrument systems. The safety instrument functions are designed and implemented in strict accordance with the technical documents specifying the safety requirements for safety instrument systems. The design of safety instrument functions is optimized through proper selection of instrumentation, structural constraints (redundancy and fault tolerance), inspection and testing schedules, as well as diagnostic techniques, to ensure that the requirements for risk reduction are met. To reasonably determine the inspection and testing cycle for safety instrumented functions (or subsystems), it is necessary to design online testing methods and relevant measures when online testing is required. During the detailed design phase, it is necessary to specify requirements such as the inspection and testing cycle sowie the testing methods for each safety instrument function (or subsystem). (6) Strictly regulate the installation, commissioning, and joint verification of the safety instrumented system. A comprehensive installation, commissioning, and joint verification plan should be formulated and effectively implemented. The processes and results of commissioning (individual instrument commissioning and loop commissioning) and verification must be documented in detail, and a management file should be established. After the construction unit has completed the installation and commissioning in accordance with the design documents, the enterprise shall, prior to putting the system into operation, organize a review and joint verification of the safety instrument system in line with **laws and regulations, standards and specifications, industry and enterprise safety management requirements, as well as technical documents related to safety requirements. This is to ensure that the safety instrument system possesses the intended functions and meets the integrity requirements, thereby being ready for safe operation. (7) Strengthen the operation and maintenance management of safety instrumented systems in chemical enterprises. Chemical enterprises must develop operation and maintenance plans and procedures for safety instrumented systems to ensure that these systems can reliably perform all their safety-related functions, thereby achieving functional safety. The safety instrument functions shall be subject to regular and comprehensive inspection and testing in accordance with inspection and testing cycles that meet the requirements for safety integrity, with the testing process and results recorded in detail. It is necessary to strengthen the management of failures in equipment related to safety instrumented systems (including equipment malfunctions, interlock actions, false operations, etc.) as well as their analysis and handling, and gradually establish a database for records of such equipment failures. It is necessary to standardize the selection of equipment related to safety instrumented systems, establish systems for the approval and evaluation of such safety instrumented equipment as well as procedures for approving changes, and continuously revise and improve these systems based on the actual usage in enterprises and equipment failures. (8) Gradually improve the management systems and internal regulations for safety instrumented systems. Enterprises should establish and improve management systems or internal technical specifications related to safety instrumented systems, integrate functional safety management into their overall safety management systems, and continuously enhance the level of process safety management. IV. Attach great importance to the management of protection measures for other related instruments. (IX) Strengthen process alarm management by formulating an enterprise alarm management system and enforcing it strictly. Alarms related to the functional safety integrity requirements of safety instrumented functions can be managed and tested in reference to those safety instrumented functions. (10) Strengthen the management of basic process control systems; for control loops related to safety integrity requirements, manage and conduct inspection tests in accordance with safety instrumented functions, and ensure the operational rate of automatic control loops. (11) Design and implement toxic, hazardous, and flammable gas detection and protection systems in strict accordance with relevant standards; to ensure their reliable operation, such systems should be independent of the basic process control system. V. Accelerate the standardization of the management of safety instrument systems in newly constructed projects from the source (XII) Starting from January 1, 2016, large-scale chemical enterprises as well as those owned or jointly operated by foreign investors that meet the relevant criteria, and that construct new chemical processing units or hazardous chemical storage facilities that fall under the category of “two key areas and one major hazard,” must design safety instrument systems that comply with relevant standards, in accordance with the requirements of these guiding principles. (13) Starting from January 1, 2018, all newly constructed chemical processing units and hazardous chemical storage facilities related to the \"two key areas and one major project\" must be designed with safety instrument systems that meet the required standards. For the safety instrument systems of other newly built chemical processing units and hazardous chemical storage facilities, starting from January 1, 2020, it is necessary to comply with the requirements of functional safety standards and design safety instrument systems that meet those requirements. VI. Actively promote the assessment of existing safety instrumented systems (14) Chemical enterprises and hazardous chemical storage facilities that operate production units or facilities classified as “two key areas and one major hazard” should, on the basis of conducting comprehensive process hazard analyses (such as Hazard and Operability Studies), determine the functions of safety instruments and the requirements for risk reduction through risk analysis, and promptly assess whether the existing safety instrument functions meet these risk reduction requirements. (15) Enterprises shall, on the basis of assessment, formulate management plans for safety instrumented systems and regular inspection and testing plans. For safety instrument functions that do not meet the requirements, relevant maintenance plans and corrective action plans must be developed, with the assessment and improvement of the safety instrument system to be completed by the end of 2019. Other chemical processing units and hazardous chemical storage facilities shall be implemented in accordance with the requirements of these guidelines. VII. Work Requirements (16) Relevant enterprises and organizations shall, in accordance with relevant laws, regulations, standards, norms, and the requirements of these guiding principles, improve their management systems and frameworks for safety instrumented systems; they should also increase investment to ensure that the safety instrumented systems in newly constructed facilities meet the requirements of functional safety standards. For safety instrumented systems in operational installations that do not meet functional safety requirements, they must be included in a remediation plan for timely correction, in order to eliminate potential accident hazards, reduce accident risks, prevent accidents from occurring, and effectively improve the inherent safety level of the enterprise. (17) Safety supervision departments at all local levels should conduct investigations and studies as soon as possible, set work objectives, identify pilot units, define schedule requirements, and guide and urge enterprises to strengthen the management of chemical process safety instrumented systems and related safety protection measures. The functional safety assessment of safety instrumented systems, the implementation of management systems for such systems, and personnel training should all be included in the scope of safety inspections and audits. Provincial safety supervision bureaus are required to compile summaries of relevant inspection activities each year, and submit them to the Third Supervision Department of the **General Administration of Safety Supervision by the end of February each year. Please have the provincial safety supervision bureaus promptly convey the spirit of these guiding principles to the safety supervision agencies at all levels within their respective jurisdictions, as well as to the relevant enterprises and design firms. **State Administration of Work Safety, November 1, 2014

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