Functional Safety Management Guide

Safety is the top priority for every organization. Numerous recent incidents have heightened the awareness that organizations need to pay attention to functional safety as well as process safety. By definition, Functional safety is overall safety of plant and equipment which depends on the correct functioning of safety-related systems and other risk reduction measures. Process safety is a blending of engineering and management skills focused on preventing catastrophic accidents particularly, explosions, fires and releases of dangerous substances such as chemicals or petroleum products. Trusted technology, Informed operations which requires attention to potentially dangerous activities and Life cycle Management which involves continuously monitoring and managing process risks are the three essential elements that encompasses process safety management.

Functional Safety Management

One of the most valuable elements of Functional safety Management is to empower the team with the clear objectives combined with the authority and resources to achieve them. In addition functional safety management is specifically noted to act as an extension to existing monitored quality systems and processes. Here are the guidelines on how to manage functional safety.

1). Managing Risks by Safety Instrumented Systems (SIS) - First and foremost a project potentially requires a safely instrumented system to manage the risk. SIS is instrumented systems that provide a significant level of risk reduction against accident hazards.  

 2). Safety Requirement Specification - Safety requirement specification must be developed. It must be specifically defined since this document is often created by one company and executed by another. Specify the required function, integrity and other requirements of the SIS. Design and implement the SIS to satisfy the safety requirements specification

 3). Validate SIS - Install, commission and validate the SIS. The safety systems must be tested, to prove that it works. This is called as validation plan. 

4). Functional Safety Assessments (FSA) - Functional safety assessments must be carried out to verify that all safety measures have been completed satisfactorily and that the safety system as installed will effectively manage plant risk. You must have at least one functional safety assessments after installation and commissioning just before start up. It includes a detailed review of hazards and risk management procedures to identify requirements for risk reduction. 

5). Periodic Review - Periodic Review procedure must be included to check that you are managing your risks throughout the operational life of your plant.

6). Operation and Maintenance - Operate, maintain and periodically proof-test the SIS. Gather Operational and maintenance data.  Plan and execute SIS proof testing procedures. Document any faults or deficiencies and correct them with a specialist.

7). Manage modifications to the SIS - It also defines requirements for management processes which includes planning, assessing, verifying, monitoring and auditing for the competence of people and organizations engaged in functional safety.

Functional Safety Trainings 

TÜV Rheinland Functional Safety Program offers trainings on different topics and application areas of Functional Safety. Anyone can participate in these trainings. The Functional Safety Engineer certificate will only be issued to those who fulfill certain requirements and who pass the exam at the end of each training successfully.

Certification

TÜV Rheinland offers many services for Automation and Functional Safety such as testing of electrical or electronic components and confirms that these safety-related products comply with the requirements of the applicable international standards and thus issues their certificates. These devices and products require a high degree of safety, reliability and quality. A failure within these devices can lead to a dangerous state for people and the environment. TÜV Rheinland assures that such danger is avoided and the product fulfills the requirements of Functional Safety to the related internationally accepted standards.

After the successful type approval of electrical and programmable products is concluded the test mark will be issued upon certification. Certificates including this test mark confirm that the certified product meets the requirements of the relevant product standards. Thus the product can be applied in the application area according to the specified requirements for this product.