SIL PROOF TEST PRACTICES -1

4.1.1 Statements of Guiding Principles

(a) The proof test of a SIS should reflect real operating conditions as accurately as possible. If
reasonably practicable, the SIS should be initiated by manipulation of the process variable
without driving the process into the demand condition. Any approach which involves
driving the process into the demand state should be accompanied by risk assessment and
additional controls.
(b) Where process variables cannot be safely or reasonably practicably be manipulated,
sufficient confidence in the correct operation of sensors should be gained by other means,
such as comparison with other measurements.
(c) The inherent difficulties associated with testing valves and in-line flowmeters should be
addressed during the design phase of SIS and additional provisions such as corroborative
measurements should be made where necessary.
(d) Proof tests should address the necessary functional safety requirements of SIS, including
functions such as response time and valve leakage class.
4.1.2 Rationale
Effective SIS proof testing should confirm the correct operation of the sensing element(s) and
actuating devices, also known as final elements. There is known to be a wide range of
techniques adopted by the end-user community in their approach to SIS testing and the
following sections provide a summary of the techniques encountered during the research. A
variety of techniques were encountered, including examples of both good and poor practice, as
were examples where a deficiency was discovered and how it was addressed or improved.
The most satisfactory test of a system will manipulate the process variable in order to achieve a
full end to end test. However, practicability is very much dependant on the nature of the
process, the process materials and associated risk, and on the tolerable upsets to the process and
to production.
4.1.3 Research Data
Testing Pressure Loops
There was unanimous agreement that process pressures should not be manipulated in order to
initiate SIS due to the potential of releasing significant stored energy [consistent with principle
4.1.1(a)].
The most popular alternative was considered to be the injection of a pressure signal in to the
measuring instrument via an isolation and vent valve arrangement positioned as close to the
primary element as possible, using a suitable fluid medium. Conversely, one end-user was of the
opinion that testing of pressure measuring instruments can only safely be carried out on special
test rigs in a workshop environment, again, because it is not considered safe to raise the pressure
of a process [inconsistent with principle 4.2.1 (d)]. Pressure loops are usually designed so that
the process input can be isolated from the measuring instrument and a calibration pump
connected at a suitable point. The pressure can then be raised to check the operation and
calibration of the instrument and so test the majority of the safety system.