INTRODUCTION: Why standardization matters for business operations

Modern manufacturing in Ukraine depends on strict safety standards to ensure occupational safety, operational efficiency and compliance with legislation. Among the key standards that determine the safety of automated systems, the SIL (Safety Integrity Level) classification is of particular importance. Selecting components that meet established SIL levels is critical to ensure safe operation of the equipment.

EXPLANATION AND APPLICATION

SIL standards are established by IEC 61508 requirements that apply to automation and safety systems used in industrial facilities. They determine the level of reliability of the security system to ensure that the risk of dangerous situations is reduced. These standards apply to industrial equipment, including electric drives, sensors, reducers, valves, and other components included in safety systems.

MAIN REQUIREMENTS

IMPACT ON MRO OPERATIONS

Compliance with SIL standards affects the following aspects of the MRO's work:

• Change in component selection requirements: Not all parts can be used in safety systems.
• Additional documentation must be maintained to certify the compliance of each component.
• Increased cost of parts collection: High SIL components are more expensive.
• The need for regular inspection and testing of security systems.

REQUIREMENTS FOR COMPONENTS

Security systems require the use of components that have the appropriate certifications:

• Pressure and temperature sensors - certification EN 60068, ISO 9001.
• Valves and fans - certification EN 13445, ISO 12100.
• Electric drives - certification EN 60034, ISO 13849-1.
• Control systems - certification IEC 61508, ISO 13849-2.

CONDUCT OF COMPLIANCE CHECK

1. Determine the risk class of your security system.
2. Select components that meet the established SIL level.
3. Fill in documentation confirming compliance.
4. Perform regular inspections and testing of the security system.
5. Keep an archive of all certificates and instructions.
6. Check all components during major repairs.
7. Keep a log of compliance with standards.
8. Conduct safety training for staff.
9. Use risk analysis tools.
10. Apply automated control systems.
11. Carry out a compliance check annually.
12. Keep all documents in the appropriate order.
13. Keep a register of changes made to the security system.
14. Perform compliance analysis when implementing new systems.
15. Keep a log of changes in the documentation.

POPULAR SUBMISSION MISTAKES

Auditors often detect the following violations:

• Using components that do not have appropriate certificates.
• Insufficient testing of security systems.
• Incorrect use of SIL levels.
• Incomplete documentation.
• Insufficient staff training.
• Failure to perform regular inspections.

SANCTIONS AND COMPLIANCE

Failure to fully comply with SIL standards may result in:

• Financial fines: up to UAH 500,000 per violation.
• Liability insurance waivers.
• Liability for tort in injury cases.
• Refusal to receive relevant certificates.
• Refusal to receive state support.

CONCLUSION

Selecting components that meet established SIL levels is critical to ensure production safety. If necessary, you can find certified components in the UNITEC-D E-Catalog.

OFFICIAL DOCUMENTS

• IEC 61508:2010 - Safety of automation systems.
• ISO 13849-1:2015 - Security in management systems.
• EN 60034:2012 - Electric drives.
• EN 13445:2017 - Valves and pipelines.
• ISO 9001:2015 - Quality management systems.
• ISO 12100:2010 - Machine safety.

UNITEC-D E-Catalog

Introduction: Why standardization matters for the functioning of production

The safety of the production process is the basis of the efficiency, quality and durability of the equipment. In Ukraine, where the industrial production base plays a key role in economic development, compliance with safety standards and technical requirements is mandatory. In particular, the calculation of SIL (Safety Integrity Level) is a critical element to ensure the safe operation of machines and equipment.

Scope: who must comply with which components, which industries

SIL certification is required for all components responsible for the safety of production equipment, including valves, valves, sensors, solenoids, level sensors and actuators. These elements are used in industries such as metallurgy, chemical industry, energy and transport.

Main requirements: table of main duties and deadlines

Below is a table that shows the basic requirements for components used in security systems.

Impact on MRO operations: how support, procurement, documentation have changed

Compliance with SIL standards causes changes in the work of MRO services. In particular, there is a need to use certified components that meet SIL requirements. This affects the selection, procurement, installation and monitoring of components. Careful documentation is also required to ensure transparency and compliance.

Component Requirements: Which parts must meet specific certifications

Components used in safety systems must have certifications such as CE, UkrSEPRO, and also comply with standards such as EN 13445-2, IEC 60947-5-1 and EN 60751. For example, valves must comply with EN 13445-2 and level sensors with EN 60751.

Conformity Check: A Practical Check for Maintenance Managers

Below is a checklist that a maintenance manager can use to ensure compliance with SIL standards.

1. Check the certification of each component for compliance with standards.
2. Ensure that all components are used in conditions that meet their specifications.
3. Perform periodic inspection and maintenance of components in accordance with SIL requirements.
4. Maintain a compliance report to ensure transparency.
5. Use only certified spare parts that meet the standards.
6. Be sure to check whether the spare parts correspond to the available documentation.
7. Establish quality control and compliance processes.
8. It is mandatory to keep a maintenance log.
9. Conduct periodic audits to ensure compliance with standards.
10. Use modern methods of risk analysis and identification.
11. Use components that meet SIL requirements.
12. Check whether the spare parts meet the requirements for operating temperature and pressure.
13. Use components that meet the requirements for electrical characteristics.
14. Use components that meet the requirements for mechanical stability.
15. Use components that meet the requirements for operational durability.
16. Use components that meet energy efficiency requirements.
17. Use components that meet the requirements for environmental safety.
18. Use components that meet the requirements for strength.
19. Use components that meet reliability requirements.
20. Use components that meet the requirements for stability.

Common Compliance Issues: What Auditors Find

Auditors often find problems related to the use of improperly certified components, lack of documentation, or faulty quality control systems. These problems can lead to higher risk, higher costs and equipment malfunctions.

Sanctions and liability: consequences of non-compliance

Failure to meet SIL standards can result in fines, loss of insurance, liability to third parties, and loss of customer trust. In the event of an accident or accident, the company may suffer large financial losses and loss of reputation.

Conclusion: choosing certified components for safety

Selecting SIL-compliant certified components is critical to ensuring production safety. United-D is a reliable supplier of certified components that meet the requirements of DSTU, EN, ISO, as well as CE and UkrSEPRO standards. You can find all the necessary spare parts and components in our e-catalogue.

UNITEC-D E-Catalog

Disposable sources: official standard documents

1. EN 13445-2: 2022 - Requirements for steel vessels and tanks
2. IEC 60947-5-1: 2021 - Requirements for switchgear
3. EN 60751: 2020 - Requirements for thermometers
4. ISO 13849-1: 2020 - Requirements for security features
5. DSTU 6089-2014: Requirements for equipment used in industrial settings
6. UkrSEPRO: Requirements for product certification in Ukraine