ISA TR84.00.03-2023
Mechanical Integrity of Safety Instrumented Systems (SIS)

Standard No.
ISA TR84.00.03-2023
Release Date
2023
Published By
Instrument Society of America (ISA)  US  /  ISA
Latest
ISA TR84.00.03-2023
 
Introduction

Overview of Automation Asset Integrity Management for Safety Instrumented Systems

The ISA-TR84.00.03-2023 standard, an important supplement to the ANSI/ISA-61511 series of standards, provides detailed guidance on the management of Automation Asset Integrity (AAI) for Safety Instrumented Systems (SIS). This technical report, published by the International Society of Automation (ISA) on July 19, 2023, aims to help industrial companies establish a systematic system for maintaining, testing, and monitoring SIS equipment to ensure that safety instrumented functions (SIFs) maintain their required safety integrity levels (SILs) throughout their lifecycles.

Background on Standard Development and Technological Evolution

With the increasing requirements for functional safety in the process industry, relying solely on initial design can no longer guarantee the long-term reliability of SISs. Actual operational data shows that over 60% of SIS failures are due to improper maintenance or inadequate testing. Based on the requirements of the ANSI/ISA-61511-2018 standard, the ISA84 committee developed this technical report to fill the standardization gap in the SIS operation and maintenance phase.

This standard, together with ISA-TR84.00.02 (SIL Verification) and ISA-TR84.00.04 (ANSI/ISA-61511 Implementation Guide), constitutes a complete SIS lifecycle management standard system. Its technological evolution reflects the important shift from pure hardware reliability to overall asset management, emphasizing data-driven preventive maintenance and predictive maintenance strategies.

Core Concepts and Terminology System

The standard establishes a complete AAI terminology system, the key concepts of which include:

2. Maintenance strategy selection: Based on equipment failure mode analysis, formulate a combination of preventive maintenance, predictive maintenance, and reactive maintenance strategies. The standard emphasizes that for safety-critical equipment, a simple run-to-failure strategy should be avoided.

3. AAI maintenance procedure development: Including pass/fail criteria development, repair/replacement assessment, human factor considerations, safety bypass procedures, etc.

Maintenance strategy comparison analysis

TerminologyDefinitionImportance
Automation Asset Integrity (AAI)A management system that ensures automation equipment is inspected, maintained, tested, and operated in a safe and reliable mannerCore Management Philosophy
As-new conditionA state of equipment free from faults and potential problemsMaintenance target state
Strategy typeImplementation methodApplicable scenariosSIS applicability
Preventive maintenanceFixed cycle executionEquipment with known degradation mechanismsHigh, recommended for critical equipment
Predictive maintenance

Site Acceptance Test (SAT): The final test to verify that the installed SIS operates according to the specifications, completing the verification process.

Technical Requirements for Proof Testing

Section 5.2.4 details the requirements for proof testing, which is a core activity to ensure the functional integrity of the SIS:

Test Interval Determination: A quantitative method is used to determine the test frequency based on equipment reliability data and the required SIL level. Test coverage should be able to detect a sufficient proportion of potential faults.

Online and Offline Testing: The standard provides implementation guidance for online testing (while the process is running) and offline testing (when the process is shut down), including techniques such as partial stroke testing and signal simulation.

Test Integrity Management: Emphasizes the impact of incomplete testing on PFD(t) and requires the establishment of a test coverage assessment mechanism.

Document Management and Data Collection

The standard requires the establishment of a complete document management system, including:

  • Equipment maintenance records and test results
  • Discovery status/legacy status data collection
  • Requirement logs and fault reports
  • Training records and qualification certificates
  • Change management documents

The appendix provides a variety of template examples, including training documents, requirement logs, fault report forms, inspection forms, etc.

Personnel Roles and Responsibilities

The standard clarifies the responsibilities of each role in the AAI project:

Maintenance technicians
RolesMain ResponsibilitiesSkill Requirements
Engineering ManagerEnsure engineering workflows are in placeSystems Engineering Management
SIS Specialist/EngineerDevelop and maintain AAI requirementsSIS expertise and standards understanding
SIS Expertise and Standards Understanding
Perform testing and maintenance activitiesEquipment-specific technical skills
Operations managersEnsure operational personnel support for AAI activitiesProcess safety and operational knowledge

Implementation Recommendations and Best Practices

Based on the standard requirements, it is recommended that companies take the following implementation steps:

Phase 1: Assessment and Planning
Conduct an assessment of the status of existing SIS equipment to identify critical equipment and their priorities. Develop an AAI management framework with clear roles, responsibilities, and management processes.

Phase 2: Procedure Development
Develop specific maintenance, testing, and inspection procedures based on equipment failure mode and analysis. Establish a document management system and data collection process.

Phase 3: Personnel Training
Provide role-specific training to ensure relevant personnel understand AAI requirements and specific operational methods.

Phase 4: Implementation and Monitoring
Execute the AAI plan, collect operational data, and continuously improve maintenance strategies and test intervals.

Technical Challenges and Solutions

The main technical challenges faced in implementing the AAI plan include:

Test Coverage Assessment: Use quantitative analysis methods to evaluate the actual coverage of proof tests to ensure test effectiveness.

Online Test Security: Develop a secure online test program to avoid introducing new risks during the testing process.

Data Management: Establish an effective data collection and analysis system to support the continuous improvement of reliability data.

Compliance and Audit Requirements

Section 4.13 of the standard specifies requirements for AAI program compliance audits, including:

  • Regular audit planning
  • Audit criteria based on ANSI/ISA-61511
  • Tracking and remediation of audit findings
  • Management review and continuous improvement

Audits should cover all elements of the AAI program, including document management, personnel qualifications, test execution, and data collection.

Summary and Outlook

ISA-TR84.00.03-2023 provides a systematic framework for SIS automation asset integrity management for the process industry. By implementing the requirements of this standard, companies can ensure that safety instrumented systems maintain their designed safety performance throughout their lifecycle, while optimizing maintenance costs and improving equipment reliability.

With the development of Industry 4.0 and digital twin technology, AAI management is becoming more predictive and data-driven. Future version updates may further integrate the Internet of Things, big data analysis and artificial intelligence technologies to achieve more intelligent asset integrity management.

ISA TR84.00.03-2023 history

  • 2023 ISA TR84.00.03-2023 Mechanical Integrity of Safety Instrumented Systems (SIS)
  • 2019 ISA TR84.00.03-2019 Guidance for Testing of Process Sector Safety Instrumented Functions (SIF) Implemented as or within Safety Instrumented Systems (SIS)
  • 2012 ISA TR84.00.03-2012 Mechanical Integrity of Safety Instrumented Systems (SIS)
  • 2002 ISA TR84.00.03:2002 MECHANICAL INTEGRITY OF SAFETY INSTRUMENTED SYSTEMS (SIS)
Mechanical Integrity of Safety Instrumented Systems (SIS)

Topics on standards and specifications

Instrumentation system sis safety instrumented system sis

Standard and Specification

ISA TR84.00.03-2012 Integrity of Safety Instrumented Systems (SIS) ISA TR84.00.03:2002 INTEGRITY OF SAFETY INSTRUMENTED SYSTEMS (SIS) ISA TR84.00.02-2022 Safety Integrity Level Verification of Safety Instrumented Functions VDI/VDE 2180 Blatt 4-2010 Safeguarding of industrial process plants by means of process control engineering - Verification of the hardware safety integrity of safety instrumented systems GSO IEC 61511-1:2014 Functional safety - Safety instrumented systems for the process industry sector - Part 1: Framework, definitions, system, hardware and software requirements ISA 84.91.01-2012 Identification and Mechanical Integrity of Safety Controls@ Alarms@ and Interlocks in the Process Industry IEC 61511-3:2016 RLV Functional safety - Safety instrumented systems for the process industry sector - Part 3: Guidance for the determination of the required safety integrity levels ANSI/ISA 84.91.01-2012 Identification and Mechanical Integrity of Instrumented Safety Functions in the Process Industry GOST R IEC 61511-3-2011 Functional safety. Safety instrumented systems for the process industry sector. Part 3. Guidelines for the determination of the required safety integrity levels


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