SIL2 and SIL3-rated Process and Safety Controller

A global technology company specializing in aerospace, building technologies, and industrial automation partnered with PSI to support the development of their next-generation process and safety automation platform. This advanced Distributed Control System (DCS) controller was designed for high-reliability environments and required compliance with SIL2 safety standards, incorporating functional safety IEC 61508, to support critical applications such as emergency shutdown (ESD), burner management systems (BMS), pipeline monitoring, and tunnel ventilation control.

PSI was engaged to contribute to the development of the multi-rack embedded microprocessor controller, which leveraged the INTEGRITY RTOS to deliver precise analog and digital I/O control. The system monitored a variety of process variables — including temperature setpoints, flow rates, and PID loop control — while providing dynamic, configurable data logging and capture functionality. The controller’s architecture enabled real-time acquisition of process data and timing metrics, supporting advanced diagnostics, statistical analysis, and runtime export of key operational variables.

In parallel, PSI also designed and developed automated test systems used to verify industrial sensors for temperature, pressure, and flow to Safety Integrity Level (SIL) 2 and 3 standards. These test systems were engineered to support multiple simultaneous testing stations and a broader array of sensors, while enhancing data capture capabilities to allow sorting and analysis by time, date, and device.

By combining deep expertise in embedded safety systems and automated industrial testing, PSI delivered a solution that advanced the client’s safety platform, improved testing scalability, and met the rigorous standards required in safety-critical industrial environments. This long-term collaboration helped strengthen product performance, reliability, and compliance across a range of industrial automation applications.