Safety Project Consulting
Functional safety is a specialist technical topic that applies across multiple industry sectors, including major accident hazard sites in the process sector (COMAH/SEVESO III) such as chemical manufacture, petrochemicals, refining, offshore oil and gas and power generation.
eFunctionalSafety provides functional safety training and consulting services based upon many years of project experience in diverse industry sectors. If your goal is compliance with IEC 61508, IEC 61511, IEC 62061 or a related standard, then we can help.
We engage by supporting end users with HAZOP, CHAZOP, LOPA, SIL determination, safety requirements specifications and SIL verification, among others.
We're also a trusted provider of training to Original Equipment Manufacturers and suppliers of safety-related instrumentation, interfaces and final elements such as actuators and valves.
Explore our Safety Life-cycle Services
Functional Safety Planning and Project Management
If you have never been involved with a safety system project, it is not necessarily immediately obvious what needs to be done, in which order, and by who. The standards provide a framework, but it takes experience to know what is important and what isn't.
We have that experience from many projects. The poorly handled projects tend to go wrong because the need for writing and following a functional safety plan simply haven't been recognised early enough.
We can provide a template plan and work with you to adapt that to meet your detailed project requirements and help manage your project more effectively.
Functional Safety Assessment and Audit - FSA
A functional safety assessment (FSA) is an independent investigation, based on evidence, to judge the functional safety achieved by one or more safety instrumented systems or safety related electrical control systems.
eFunctionalSafety has developed a full FSA procedure and detailed checklist that covers the requirements of multiple standards, including IEC 61508, IEC 61511 and IEC 62061.
Hazard and Operability Studies - HAZOP
We can facilitate your team in determining process hazards and operability issues using the HAZard and OPerability (HAZOP) methodology.
Guided by IEC 61882 or your own HAZOP procedure, we always record a HAZOP such that later phases of activity such as LoPA or other forms of SIL study will have the necessary detail.
Control HAZOP - CHAZOP - Security CHAZOP
Control HAZOP, or CHAZOP is a specialist technique usually applied after process HAZOP. CHAZOP is advised for new or modified control systems and programmable devices monitoring, controlling or providing automated safety functions for process and equipment. In such systems, hazards may be caused when either a hardware or systematic failure occurs, or when the controls actioned by the system deviate from their intended behaviour. We have extended our proven CHAZOP procedure to include Security CHAZOP to check for security vulnerabilities of existing industrial control and safety systems.
Layer of Protection Analysis - LoPA
LoPA is becoming the "go-to" method for many companies in the determination of protection layer credit. With the correct tolerable risk guidelines it can be used to determine the Safety Integrity Level (SIL) for your instrumented protection functions.
We can provide an experienced LoPA facilitator who will guide your team in correctly applying the technique without the need for costly re-work.
Safety Requirements Specification
Safety requirements are the cornerstone of any safety instrumented system (SIS) or safety related electrical control system (SRECS) project. Requirements have to be carefully prepared and kept up to date.
We can provide starting templates that have been proven on previous projects and then support the development and update of the requirements for your project.
Device SIL Capability Assessment
Devices being used in safety functions need very careful selection. We have the experience to be able to look at your preferred sensors, logic solvers and final element equipment and give an unbiased view about the SIL capability that can be achieved by the design.
This service is usually a precursor to SIL verification, but can be provided as a stand-alone assessment if required.
SIL Verification of Safety Functions or Devices
Design verification of Safety Integrity Level (SIL) is required for all projects that wish to demonstrate that safety functions meet best practice engineering. We can help to provide your evidence of meeting probability of failure (PFD or PFH) and hardware fault tolerance (HFT) for any SIL requirement. We have significant project experience working with IEC 61508, IEC 61511 for process safety and IEC 62061 for machinery.
We can also assist with verification services for only part of a function such as a final element valve & actuator.
Safety System Application Program Verification
Either as part of a functional safety assessment, or as an individual service, we can provide design assurance that application programs (software) have met best practice standards.
We do not write the code, but we do have the experience of reviewing detailed PLC software design specifications that use ladder logic, function block diagram and sequential function chart.
Validation Planning and Support
We can assist at the testing and validation stage of a safety system project by helping to write the necessary test plans. Typically our involvement is best engaged at or after the Factory Acceptance Testing (FAT) of a new or modified system.
If we're not involved in the project development or writing the test plans then we can provide a fully independent Functional Safety Assessment (FSA).
We supported a major new refinery project destined for Kuwait by providing the SIL study facilitator for three different units - Hydrogen Production Unit, Amine Regeneration Unit and Sulphur Recovery Unit. The project support was provided in phases, leading multi-discipline engineering teams of 15+ people in the SIL study workshops. Our deliverable was a SIL determination report for each unit, ready to be used by the project team in the creation of the safety requirements specification for the safety instrumented functions on the project.
Case Study #1
We facilitated a team study for a major extension of a batch pharmaceutical process, using the Layer of Protection Analysis (LoPA) technique to analyze identified hazards and determine safety integrity levels (SIL). The project involved providing an amended LoPA procedure, as the end user had previously been using calibrated risk graph for earlier studies. Several stages of study were undertaken to analyze more than 40 hazardous scenarios, resulting in a unique LoPA worksheet for each scenario and a summary report of the findings.
Case Study #2
A Stage 4 / 5 Functional Safety Assessment (FSA), according to IEC 61511 FSA recommended stages, was required for a safety instrumented system undergoing upgrade on a chemical plant. We provided the lead assessor to scope, plan and deliver the assessment. Firstly, the existing system was assessed to check for any non-conformance issues with important aspects of operating and maintaining the SIS, including a review of proof test records. Following this, the SIS modification project was assessed for all stages including hazard assessment, LoPA, safety requirements and the design changes to hardware and software of the system. The FSA also witnessed physical validation testing prior to start-up.