GB/T 32202.2-2026Functional safety of safety instrumented systems in oil and gas pipelines - Part 2: Acceptance requirements (English PDF)

5.1 Acceptance Phase

5.1.1 Functional safety acceptance activities should be conducted throughout the entire lifecycle. This should be in accordance with GB/T 21109 (all parts) and oil and gas pipeline safety instruments. For the system lifecycle activities (Figure 1), functional safety acceptance activities should be performed at the following nodes.

---Node 1.SIS Design Review. This should be conducted after the SIS design is completed (but before approval), i.e., during the lifecycle of the safety instrumented system for oil and gas pipelines. This will take place after activities 1-4 are completed.

2.Factory Acceptance. This should be conducted after the integrator has completed the integration of the safety instrumented system and internal testing, specifically the oil and gas piping. This will be carried out after the completion of Safety Instrumented Lifecycle Activity 6.

3.On-site Acceptance. This should be carried out after the on-site testing components, actuators, and cabinet installation and commissioning are completed, i.e., after the oil and gas pipeline installation is finished. The full instrument lifecycle activity will be conducted after 9 months.

4.Pre-start Safety Verification. This should be carried out after training of relevant personnel on the safety instrumented system and completion of on-site acceptance testing. This will be carried out after all Safety Instrumented Lifecycle Activities 8 and 10 for oil and gas pipelines have been completed.

5.Handover and Acceptance. This should be conducted after the safety verification before startup of the safety instrumented system is completed, i.e., after the safety instrumented system for oil and gas pipelines has been successfully started. It will be carried out after the life cycle activity 11.

5.1.2 Acceptance activities shall be conducted in accordance with Chapters 6 to 10, including SIS design review and pre-launch safety validation. The SIS design and pre-operation assessment were conducted, and the assessment report of the assessment activities can be directly reviewed.

5.1.3 Acceptance activities may be supplemented at various stages of the project lifecycle, depending on the actual situation of the project execution.

5.2 Acceptance Requirements

5.2.1 The acceptance procedure for a safety instrumented system should be determined by the relevant personnel involved in each stage of the safety instrumented system's lifecycle, based on the actual project conditions. The staff confirmed this together.

5.2.2 Before acceptance, the acceptance organization shall establish an acceptance team and clarify the responsibilities of each member.

5.2.3 The acceptance team shall prepare an acceptance plan and establish the acceptance site and related ancillary facilities. The acceptance plan shall include the acceptance time, location, and personnel. The acceptance plan should include the composition, acceptance content, and acceptance criteria, and should be confirmed by the acceptance organization.

5.2.5 FAT can be implemented by the system integrator with user participation.

5.2.6 The system integrator shall complete all hardware and software integration, application development, loading, and completion before the FAT (Fixed Application Test). Internal testing of the system. The scope of internal testing should include all the contents specified in 7.2.7.

5.2.7 The system integrator shall prepare a FAT test plan in accordance with the relevant requirements of this document. The FAT test plan shall include the test work... The content and schedule are to be finalized by the user.

5.2.8 Safety instrumented systems shall not be shipped to the site until a factory acceptance certificate has been signed.

5.2.9 SAT should be implemented by the system integrator, with the cooperation of the system construction unit, equipment supplier and construction unit, and the user supervision.

5.2.10 SAT shall conduct actual operation tests on safety function circuits. Figure

1.Lifecycle and Acceptance Milestones of Safety Instrumented Systems for Oil and Gas Pipelines Note

1.Depending on the actual project situation, the output of the feasibility study stage may be in the form of a project proposal or other forms. Note

2.Preliminary design is called scheme design. 6.SIS Design Review

6.1 Review Basis SIS reviews should be conducted based on the following latest, approved information.

---The design should comply with the laws, regulations, standards, and norms;

6.2 Review Content

6.2.1 The design should comply with the laws, regulations, standards, and specifications, including the following.

---The completeness of the laws, regulations, standards, and norms followed;

---The accuracy of the laws, regulations, standards, and norms followed;

---Applicability of the laws, regulations, standards, and norms followed.

6.2.2 The hazard analysis and risk assessment report should include the following.

---Each identified hazardous event and risk factor;

---The likelihood and outcome of the event;

---Consider normal operation, start-up, shutdown, maintenance, and emergency shutdown scenarios;

---Identify additional risk reduction requirements to achieve the desired safety;

---Measures taken to eliminate or mitigate dangers and risks;

---Assumptions made during risk analysis include equipment failure rate, potential demand rate, operational constraints, and the possibility of human intervention. Credibility;

---The allocation of safety functions in the protection layer takes into account the potential performance reduction caused by common-cause failures;

---Identify the safety functions implemented by the safety instrumented system.

6.2.3 Check the safety requirements specification, which should include the following.

6.3 Review Report

6.3.1 Upon completion of the review process, a review report shall be prepared and signed and confirmed by the acceptance team.

6.3.2 The review report shall include all the contents of 6.2.

6.3.3 Non-conformities discovered during the review process should be recorded in the Non-conformity Table, which is shown in Table A.1 of Appendix A.

7.2 Acceptance Items

7.2.1 Check the completeness of the technical documents listed in 7.1.The check record is shown in Table B.1 of Appendix B.

7.2.2 Check the consistency of the type, quantity, and technical parameters of the hardware with the design documents, and check the appearance of the hardware for stress deformation and mechanical damage. Bad, see Table B.2 for inspection record.

7.2.3 Check the consistency between the type, quantity, technical parameters, license, and version of the software and the design documents. The check record is shown in Table B.3.

7.2.4 Check the consistency and rationality of the cabinet installation with the design drawings. The inspection record is shown in Table B.4.

7.2.5 When non-safety functions are configured in a safety instrumented system, it should be verified that the non-safety functions do not interfere with the normal execution of safety functions, and the records should be checked. See Table B.5 for details.

7.3 Acceptance Report

7.3.1 After the factory acceptance test is completed, an acceptance report shall be prepared and signed and confirmed by the acceptance team.

7.3.2 The acceptance report shall include all the contents of

7.2 and the acceptance certificate.

7.3.3 The acceptance certificate shall give a clear conclusion based on the acceptance criteria, including acceptance, conditional acceptance, or non-acceptance. The format is shown in Appendix C. Table C.1.

7.3.4 Any non-conformities discovered during the acceptance process should be recorded in the Acceptance Non-Conformity Table, as shown in Table A.1.

7.3.5 Test non-conformities should be classified as follows:

--- Rectification was carried out during the FAT process;

---After FAT, the system needs to be rectified before being transported to the site;

---To be rectified on-site.

8.2 Acceptance Items

8.2.1 Check the completeness of the technical documents listed in 8.1.The check record is shown in Table D.1 of Appendix D.

8.2.2 Check the consistency between the hardware quantity and technical parameters and the design documents; check the hardware appearance for stress deformation and mechanical damage; check... See Table D.2 for the records.

8.2.3 Check the consistency between the software license, version, and technical parameters and the design documents. The check record is shown in Table D.3.

8.2.4 Check the consistency and rationality of the cabinet installation with the design drawings. The inspection record is shown in Table D.4.

8.2.5 The test system functions to meet the design requirements. The test should include the following.

---Power supply test, see Table D.5 for test results;

---System basic function test, see Table D.6 for the test table;

---Redundancy test, see Table D.7 for the test table;

---Input circuit test (analog and digital quantities), see Table D.8 for the test table;

---Circuit safety function test, see Table D.9 for the test table;

---Commonality test, see Table D.10 for the test form;

---Test of auxiliary operating facilities; see Table D.11 for the test form;

---Bypass function test, see Table D.12 for the test table;

---Information security testing, see Table D.13 for the test schedule;

8.3 Acceptance Report

8.3.1 After the on-site acceptance test is completed, an acceptance report shall be prepared and signed and confirmed by the acceptance team.

8.3.2 The acceptance report shall include all the contents of

8.2 and the acceptance certificate.

8.3.3 The acceptance certificate should provide a clear conclusion based on the acceptance criteria, including acceptance, conditional acceptance, or non-acceptance. The format of the acceptance certificate is as follows: See Table C.1.

8.3.4 Any non-conformities discovered during the acceptance process should be recorded in the Acceptance Non-Conformity Table, as shown in Table A.1.

8.3.5 Test non-conformities should be classified as follows:

---Improvements made during the SAT testing process;

---After SAT, make corrections before pre-launch safety verification.

9.1 General Requirements

9.1.1 A pre-startup safety validation of the SIS should be conducted before commissioning to determine all relevant aspects of the SIS, including equipment, facilities, operating procedures, and training. Whether the relevant content is complete and sufficient, and whether it meets the conditions for safe operation.

9.1.2 Pre-operation assessment of SIS can employ either simple or detailed verification methods. For new construction, expansion, and large-scale renovation projects, detailed verification is preferable. Use detailed confirmation; for small-scale renovation projects, simple confirmation is preferable.

Note. Simple review refers to reviewing only the changed parts as listed in 9.3; detailed review refers to reviewing all the contents listed in

9.3 for the entire SIS. Content review.

9.1.3 Before starting the SIS, it should be safe to start it and then put it into operation.

9.2 Basis for Confirmation Confirmation should be based on the following information.

---Design documents;

---Change documents (if any);

---Change Impact Analysis Report (if any);

---SAT Acceptance Report;

---Safety Requirements Specification;

---SIS Operation and Maintenance Manual;

---Information Security Compliance Assessment Report;

---Personnel training content and records (including operators, maintenance personnel, and management personnel).

9.3 Confirmation Content

9.3.1 Confirm that the SAT acceptance has been completed and that the SAT acceptance conclusion is qualified, and that all rectification items have been rectified.

9.3.2 Confirm that all bypass functions except for driving bypass have been restored to normal.

9.3.3 Confirm that all testing facilities have been removed or restored and all test media have been cleared.

9.3.4 Confirm that all overshoot, forced, and other measures set during the debugging process have been deactivated.

9.3.5 Confirm that the safety instrumented system has undergone a network information security assessment, and that the assessment results meet the corresponding network security level protection requirements. Require.

9.3.6 For design changes that occur during installation and implementation, it has been confirmed that change impact analysis has been conducted and change management has been implemented. The relevant records have been reviewed.

9.3.7 Confirm that the SIS system hardware meets the following requirements.

---The hardware has SIL certification documents that meet the SRS requirements.

---Hardware operating conditions meet the requirements of the SIS physical operating environment. - Temperature range; - Humidity range; - Vibration and shock; - Polluting gases; - Dust; - Electromagnetic interference/radio frequency interference (EMI/RFI); - Power rating.

---Preventive measures have been taken to protect the SIS environment from electromagnetic interference, and the following aspects have been considered. - The internal design of SIS; - Actual installation (e.g., separating power and signal cables); - Protects all inputs and outputs from damage caused by voltage spikes induced in the input cables; - EMC testing procedures.

---Communication protocols between devices have been defined. The SIS interface has been defined in terms of data display and alarms.

---The SIS interface is independent of the BPCS interface. If it weren't independent, measures would already be in place to prevent undesirable changes when the BPCS changes. SIS logic change.

9.3.8 Confirm that the SIS system operation and maintenance manual includes the following.

---Standard system operation procedures;

9.4 Confirmation Report

9.4.1 After the safety verification before startup is completed, a verification report shall be prepared and signed and confirmed by the acceptance team.

9.4.2 The confirmation report shall include all the contents of

9.3 and the confirmation certificate; the report shall be clearly structured, accurately worded, unambiguous, and traceable; When a non-compliance item is identified, corrective measures and plans should be clearly defined.

9.4.3 The certificate of acceptance should provide a clear conclusion based on the acceptance criteria, including whether the device can be started, can be started after rectification, or cannot be started. See Appendix E for the formula.

9.4.4 Non-conformities discovered during the verification process should be recorded in the Non-conformity Record Table, as shown in Table A.1.