Maintaining a SIL Rated System from Commissioning Onwards

DEKRA Open Courses ATEX/DSEAR IChemE Accredited

This course is suitable for anyone who would benefit from a broad understanding of this important safety related area and will cover the background of IEC61508/11 SIL development and its management requirements. The presentation will go on to explain SIL determination techniques such as Risk Graph & Layers of Protection Analysis (LOPA), which are common methods within the process industries. Workshops will reinforce the learning of these techniques.

  • This course is for maintenance engineers who are required to maintain a SIL-rated safety instrumented system (“SIF”) and can be asked to be involved in installation and commissioning.
  • The course helps maintenance engineers who are often involved in some installation and, more extensively in commissioning as their team around them wants the maintenance engineer to get to know the system. However, very importantly, it is important for maintenance engineers to know what they need to get out of the installation and commissioning process, from a completely practical perspective and for a legal perspective.
  • The course covers the legal requirements for commissioning and maintenance of SIL-rated systems protecting any dangerous substance. Thus the maintenance engineer discovers what needs to be included and covered at installation, commissioning and during maintenance of the SIF. During the life of the SIF the course looks at replacement and repair activities that occur. The course also covers the relevant aspects of the management of changes as well as full and partial proof testing. The time allowed for maintenance, repair and replacements work is also an important part of this course.
  • The result is that anyone involved in maintenance of a SIL-rated safety instrument understands what they need, what they can find, and what is required of them.


This training course includes exams and the results of the exams are shown on the candidate’s certificate. Extensive opportunities to discuss the various issues raised with the lecturers will be provided. Following completion of the course, delegates should be able to:

  • participate in, and contribute towards, future SIL assessments within their own workplace
  • appreciate the elements of safety system design and the importance of operations and maintenance management to overall safety.

Module 1

The introduction starts with the status of IEC61511 and IEC61508 and gives an understanding of what the SIL rated safety instrumented system actually covers as well as its legal status. The foundation understanding is put in place the differences between a SIF, a SIS and a SIL rating. An example reliability of an instrumented loop is considered to show that the SIL rating is the entire loop. The course now moves on to pick out important details of the design and a realisation that safety includes all the other layers of protection. An understanding is given that most safety trips should not be SIL rated and only High Integrity trips are SIL rated.

Module 2

An understanding of demand rate is uncovered. We then look at the important information for maintenance to be taken from the specification documents. The content now unpacks the meaning and importance of MTTR to the maintenance personnel. The course looks at installation aspects and the importance of the very first proof test at commissioning and how the proof test schedule flows from it. The course looks at regulatory requirements under DSEAR and how they impact in the UK on the commissioning and maintenance of a SIL rated system.

Module 3

This module reviews all the requirements for installation and commissioning of the SIL rated system. Audit of the system, validation and the first full proof test at the end of commissioning are all covered as well as actions to comply with the DSEAR regulations for Dangerous Substances. The course describes what to do when errors are discovered during installation, commissioning and proof testing of the SIL rated system.

Module 4

The course moves on to the operating life and shows how properly documenting a demand on the SIL rated trip can be used to save money overall. The course also coves how maintenance engineers can optimise their safety and the safety of others during testing. What an audit of the system should cover and the importance of audits of SIL rated systems, is reviewed in the course.

Module 5

In the final section: The course covers the importance and significance of like-for-like replacement and proof testing of replacements and the management of changes. The final module also covers Safety Management and the Legal requirements of the Basis of Safety.

A key aspect to our courses is for our delegates to gain the knowledge and solutions applicable to their own situations, so numbers are capped to ensure we have sufficient time for your feedback and early booking is therefore recommended.

Phone: +44 (0)23 8076 0722 - Fax: +44 (0)23 8076 7866

Additional Information
This course is provided by the Author of the I.Chem.E’s book “Using Risk Graphs for Safety Integrity Level Assessment”, a book that is now named and included in IEC61511 2nd edition Part 3. The provider of the course has worked at several locations with the maintenance teams looking after safety instrumented systems.

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