exida® helps a chemical producer close gaps in functional safety design and implementation before hazards are introduced to the process.
Iowa Fertilizer Company, Wever, IA USA
Identifying gaps in IEC 61511/ISA 84 implementation and effecting resolution rapidly
Perform a gap assessment against IEC 61511/ISA 84 requirements and systematically work through the lifecycle to close the gaps. Establish procedures and processes to support IFCo into the Operation and Maintenance phase of the functional safety lifecycle.
Iowa Fertilizer was able to start up the facility with the confidence that the functional safety lifecycle is compliant with IEC 61511/ISA 84 requirements to Stage 3 FSA and that process risk is effectively managed across the facility.
The Iowa Fertilizer Company (IFCo) facility in Weaver, IA is a world-scale greenfield fertilizer plant with a capacity of up to 3 million metric tons of nitrogen fertilizers. Contracted by a global producer of fertilizers and industrial chemicals, a project management team and multiple engineering design firms were to deliver a turnkey facility. Prior to start-up the operations team conducted a thorough review of the project design documentation and contacted exida for assistance in addressing potential gaps with the HAZOP and LOPA records. The gaps raised concern about the adequacy of the Safety Instrumented System (SIS) including the potential for previously unidentified risk, insufficiently mitigated risk, and incomplete implementation of the functional safety lifecycle. The owner’s intent was for the facility to be ANSI/ISA 84 (IEC 61511) compliant. As the project documentation was reviewed, it became apparent that contractors had a very different expectation on how to achieve compliance. A key lesson learned is the importance of beginning with a Functional Safety Management Plan to guide all contractors and technology providers on the owner’s expectations for implementation of the Functional Safety Management Lifecycle.
exida provided IFCo with assistance in identifying and closing gaps in all phases of the Functional Safety Lifecycle. These include:
This project is the subject of the paper “Functional Safety Management Planning” jointly authored by exida and Iowa Fertilizer and presented at the 2017 Mary Kay O’Connor Process Safety Symposium.