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Case Studies

International Operator: Functional safety

November 20, 2023
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In order to continue to operate safely, starting in 2018, our client began to undertake an update to the way they managed functional safety across all of their assets. Katoni began supporting them in these activities and quickly became the sole provider of support for key functional safety related services.

This operator identified that the way it controlled and handled its functional safety could be improved: a lot of the information was not controlled, it was spread across different reports from multiple vendors, and there were gaps in control.

Katoni began by undertaking an FSA4 (Functional Safety Audit) initially focusing on one asset before moving on to 6 further assets.

The first step of the FSA4 was improving control of information by performing a validation analysis of all Safety Instrumented Functions (SIFs) on each platform. This comprised of:

  • Identification of SIFs from P&IDs
  • Definition of SIF functional description
  • Potential hazard if SIF fails on demand
  • Identification of primary final elements
  • Identification of the instrument set point
  • Suggested Integrity Level (IL) for the SIF between N/R and IL 4
  • Identification of SIFs which had not been documented or analysed previously
  • Identification of conflicts of data

This original scope included creating over 4200 entries of SIFs into the clients functional safety database.

The next phase of this project involved undertaking a detailed Process Hazard Analysis (PHA) for all SIFs which had a determined IL of 1 or greater from the screening process. The PHAs were completed in lieu of HAZOPs. This scope commenced on a single asset and has since been completed for a second asset with a third imminent. This scope included:

  • Detailed analysis of each SIF
  • Creating a documented record of the purpose of the SIF to detail its purpose
  • Identification of equipment design conditions, HP/LP interfaces
  • Review of potential overpressures / overtemperatures
  • Detailing normal operating conditions
  • Identification of a detailed hazard description
  • Identification of independent protection layers
  • Generation of a list of supporting documentation required to supplement the PHA such as PSV calculations, Process Safety Time (PST) calculations, release volume calculations, etc.
  • Risk Graph Assessment (RGA) meetings with TA’s; Instrument, Process, Tech Safety, Rotating Machinery chaired by our Lead Process Engineer.

This project is still ongoing, and each asset is taking approximately 8 months to complete. The ambition is to complete all assets using the same method.

The final step of the process Katoni are undertaking is Layer of Protection Analysis (LOPA) sessions. All SIFs which the RGA has assessed as having an IL greater than or equal to 2 are being carried forward into LOPA. The PHA completed is being utilised as the precursor to the LOPA and as this has been completed to a high quality level it is speeding up the process of LOPA which can typically take a considerable length of time. Katoni are working to clear the holds which have been carried forward from the RGA sessions.

Prior to the LOPA Katoni have carried out all process safety calculations associated with all SIFs which were identified as being required. Our client is taking this opportunity to reassess all PSVs, PST and overpressure calculations based on rotating machinery as part of this process. Katoni is undertaking all of this work.

Katoni have successfully helped our client develop the whole functional safety methodology, which has resulted in improvements made in the process, development of the PHA framework and improvements to the database including full record keeping of actions and requirements.

This approach to functional safety has been commended by HSE as being the best in the industry and Katoni have played a critical role in developing this system. Our methods, approach and collaborative methods has helped develop this system.

From the work completed managing the functional safety scopes, Katoni have assisted in developing a better methodology to conduct equipment criticality assessments to capture the work completed on the functional safety side and utilise the data to better identify maintenance of equipment. The ultimate goal for this is to capture savings and optimisations for spares holding, and offshore manhours.

Katoni are currently conducting a pilot assessment to prove this methodology.

To date Katoni have spent approximately 13,000 hours undertaking functional safety work for this client alone,  and have chaired approximately 350 hours of functional safety reviews.

Key benefits in engaging Katoni:

  • Working with a collaborative partner who will help to improve a clients systems and work to get the best solution, rather than maximise the amount of hours spent doing things inefficiently.
  • Subject matter experts in functional safety who can offer repeatability in assessments a key requirement in a successful functional safety project.
  • Flexible in approach to be able to react to client issues, or information gaps in cooperative manner.
  • Our knowledge and understanding how offshore processing assets operate and interactions between systems add value to review sessions.  We don’t merely facilitate the sessions, we participate and input our knowledge and lessons learned from extensive experience.
  • Our understanding of the process design and how excursions from design parameters impact process conditions e.g pressure, level, temperature etc.
  • Clear documented records allowing future revalidation exercises to be completed efficiently