How do you design and implement a safety instrumented system (SIS) for a robotic process?

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Robotic processes are widely used in industrial automation to perform tasks that are hazardous, repetitive, or require high precision. However, robotic processes also pose risks to human operators, equipment, and the environment if they malfunction or fail. To ensure the safety and reliability of robotic processes, you need to design and implement a safety instrumented system (SIS) that can detect and respond to dangerous situations. In this article, you will learn what a SIS is, how it works, and what steps you need to follow to design and implement one for a robotic process.

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Rawand Abdulla Mahmood

Instrument & Control Engineer
Richard Kelly CFSE

Functional Safety Consultant | Helping Engineering Leaders to Deliver Nuclear Safety System Projects | Optimise…
Steve H.

Control Systems Supervisor

1 What is a SIS?

A safety instrumented system (SIS) is a set of hardware and software components that monitor and control a process to prevent or mitigate hazardous events. A SIS consists of three main elements: sensors, logic solvers, and final elements. Sensors measure the process variables, such as temperature, pressure, level, or flow, and send signals to the logic solvers. Logic solvers process the signals and execute the safety logic, which is a set of rules and calculations that determine the appropriate actions to take. Final elements execute the actions by manipulating the process equipment, such as valves, switches, motors, or brakes.

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Richard Kelly CFSE

Functional Safety Consultant | Helping Engineering Leaders to Deliver Nuclear Safety System Projects | Optimise Designs, Streamline Design Reviews, and Win Bids—Even at Higher Prices.
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I disagree with the term safety instrumented system in this application. SIS is unique to BS61511 process industry. Therefore, this terminology is incorrect.

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2 How does a SIS work?

A SIS works by performing safety functions, which are specific actions that achieve or maintain a safe state of the process. For example, a safety function for a robotic arm could be to stop its movement if it detects an obstacle or a human in its path. A safety function has a trigger condition, which is the criterion that activates the function, and a response time, which is the maximum time allowed for the function to complete. A SIS also has a safety integrity level (SIL), which is a measure of how reliable and effective the system is in performing its safety functions. The higher the SIL, the lower the probability of failure on demand (PFD), which is the likelihood that the system will not work when needed.

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Rawand Abdulla Mahmood

Instrument & Control Engineer
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A SIS works by performing safety functions, which are specific actions that achieve or maintain a safe state of the process. A safety function has a trigger condition, which is the criterion that activates the function, and a response time, which is the maximum time allowed for the function to complete. A SIS also has a safety integrity level (SIL), which is a measure of how reliable and effective the system is in performing its safety functions. The higher the SIL, the higher (RRF), which leads to more reliable systems. And again, we should remember to not put all eggs in a basket and have a proper LOPA.

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3 How do you design a SIS?

To design a SIS for a robotic process, you need to follow a systematic and structured approach that involves several steps. The first step is to identify the hazards and risks associated with the process, such as fire, explosion, collision, injury, or damage. The second step is to define the safety requirements and objectives, such as the safety functions, the trigger conditions, the response times, and the SILs. The third step is to select and design the SIS components, such as the sensors, the logic solvers, and the final elements, according to the safety requirements and standards. The fourth step is to verify and validate the SIS design, by testing, reviewing, and documenting its performance and functionality.

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Steve H.

Control Systems Supervisor
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This is just AI parroting information with no context.. terrible. SIF design is an extremely critical process and is vital in protecting life, property and the environment and AI should not be involved in any way, shape or form.

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4 How do you implement a SIS?

To implement a SIS for a robotic process, you need to follow a careful and coordinated process that involves several steps. The first step is to install and commission the SIS components, by following the installation instructions, wiring diagrams, and checklists. The second step is to calibrate and configure the SIS components, by setting the parameters, ranges, and thresholds of the sensors, the logic solvers, and the final elements. The third step is to perform functional testing and safety testing of the SIS, by simulating the normal and abnormal scenarios and verifying the expected outcomes and behaviors. The fourth step is to document and record the SIS implementation, by updating the manuals, drawings, and records.

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5 How do you maintain a SIS?

To maintain a SIS for a robotic process, you need to follow a regular and consistent process that involves several steps. The first step is to monitor and audit the SIS performance and operation, by collecting and analyzing the data, events, and alarms from the sensors, the logic solvers, and the final elements. The second step is to inspect and service the SIS components, by checking their condition, functionality, and calibration. The third step is to repair and replace the SIS components, by fixing any faults, defects, or damages. The fourth step is to modify and update the SIS design and configuration, by implementing any changes, improvements, or upgrades.

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How do you design and implement a safety instrumented system (SIS) for a robotic process?

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1 What is a SIS?

2 How does a SIS work?

3 How do you design a SIS?

4 How do you implement a SIS?

5 How do you maintain a SIS?

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