Cost effective alternative in meeting the required Safety Integrity Level (SIL)

Demonstrating process safety has always been one of the paramount concerns of Engineering, Procurement, and Construction (EPC) companies in the industrial sector, especially with the development of stringent standards such as IEC-61508 and IEC-61511. One of the means of process safety demonstration is through Safety Integrity Level (SIL) Verification. In some cases, SIL verification results show that several Safety Instrumented Functions (SIFs) do not meet their required SIL; and one of the actions is to add new SIF components. However, with the addition of new components comes a change order, which eventually leads to added cost and time overruns for design and construction projects; and in some instances, introduces additional risks to the system. This paper presents a case study based on the SIL verification report of a design and construction project. The scenario of interest involves the over-pressurization in the High Pressure (HP) Flare Knock-Out (KO) Drum which activates a SIF that will close two Shutdown Valves (SDVs), preventing added pressure to be delivered to the KO Drum. Seeing as two SDVs in a 2oo2 configuration need to be closed, the SIF was not able to meet its target failure measure of SIL 2. Three cases were set, in order to meet the required SIL. The first one involves adding new SDVs; the second case made use of upstream existing SDVs, while the third one is similar with the second but differs in configuration of the SDVs. SIL verification was performed for all three cases through the Fault Tree Analysis modeling technique. Results of this study suggest that using existing instruments can be a cost effective way of meeting the required SIL, which eliminates all the hassle and potential risk introduced when bringing in new instruments to the design.