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Functional Safety Management

Workplace Safety Regulations require Operators of industrial plant to ensure that safety risks are reduced to an acceptable minimum. Compliance with industry best practice and ALARP principles can be demonstrated by implementing a Functional Safety Management (FSM) System in accordance with IEC 61511. Latest version of the standard issued in 2017 contains new requirements that impact Operators of new and existing plant.

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Hazard and Risk Assessment (HAZOP, FTA, QRA)

The first step of the Safety Life Cycle is a Hazard and Risk Assessment (HRA) to determine the risks associated with a particular plant or process. Level of analysis can range in complexity from ‘What if’ Checklist to HAZOP, FMEA, FTA up to QRA.

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Cyber Security

Cyber security is a growing risk to all critical infrastructure and industrial process plant. The latest edition of IEC 61511-1 (Ed. 2) requires that a security risk assessment be carried out already in the HRA phase. Further detailed security assessment (including audit of existing plant) may be carried out as per IEC 62443.

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Risk Reduction and SIL-Analysis (Risk Graph, LOPA)

Safety mitigations identified during HRA may include Safety Instrumented Functions (SIFs). The level of risk reduction and corresponding integrity requirements for the SIFs are defined via a risk reduction analysis such as calibrated risk graph or LOPA.

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Safety Requirements Specification

The Safety Requirements Specification (SRS) is the link between the analysis and implementation phases of a project. The SRS should be prepared in detail as per IEC 61511 and updated throughout the Safety Life Cycle.

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Verification und Validation

Verification and Validation of safety systems should be carried out throughout the Safety Life Cycle. A key verification activity takes place before implementation to ensure that SIF’s ‘as-designed’ meet the requirements of the SRS. Validation is necessary prior to setting into operation (IEC 61511-1 clause 15).

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Functional Safety Assessments and Audits

Functional Safety Assessments (FSAs) are an integral part of the Safety Life Cycle. IEC 61511 defines five FSA’s, of which FSA Stage 3 and Stage 4 are considered to be mandatory. In addition to verification, validation and FSA, independent Audits confirm compliance with the Site FSM Plan.

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Operation, Maintenance, Modifications

FSM requirements continue throughout the operation, maintenance and modification phases of the Safety Life Cycle. Particularly for legacy plant, there may be gaps in FSM activities, ranging from minor documentation issues up to potential degradation of SIF-function due to inadequate proof testing or exceedance of equipment useful life.

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