Process – Functional Safety

Training & Certification

Program
In accordance with IEC 61508 / IEC 61511
Your Training at
TÜV SÜD Academy

Functional Safety training on IEC 61508 & IEC 61511 ▪ Functional safety standards
▪ Functional Safety Engineer (Fser) Lv. 01 ▪ Module 2 - The Basics of Functional Safety
▪ Functional Safety Professional (FSP) Lv. 02 ▪ Functional safety management
Today’s industry needs cross-disciplinary knowledge to achieve the maximum ▪ Lifecycle concept
quality, reliability and safety. Constantly changing functions in mobile and ▪ Documentation
stationary systems require companies to reach high levels of expertise,
particularly with regard to safety, in order to master this complexity. Safety ▪ Implementation and monitoring
regulations insist that persons with responsibilities in these environments must ▪ Verification, validation, assessment, and audits
possess adequate specialist knowledge. ▪ Modifications
Employers must train and certify their functional safety employees to meet the
demands of the business and standards. The FSCP confirms the individual as ▪ Competency
an expert in the Process industry and is a highly sought-after qualification. For
a business, having a team of certified professionals demonstrates its Day 2:
commitment to functional safety and fulfils one of the requirements of IEC ▪ Module 3 - Hazard and Risk Analysis
61508- IEC 61511 qualification
▪ How much safety is enough?
Course introduction: ▪ Risk management

Based on years of practical experience in the field of Functional Safety and

▪ Hazard identification
participation in relevant standardization committees we impart you with the ▪ Hazard analysis
required knowledge relating to the existing IEC 61508/61511 standard for ▪ Overview of risk reduction techniques
safety-relevant electrical / electronic systems. This Training provide detailed
information and example / discussion for understanding and mastering the ▪ Risk graph
requirements of IEC61508 / IEC61511 functional safety. Evening study time and ▪ Risk matrix
problem solving is recommended. The course is designed as per the latest ▪ LOPA
standard for Functional safety IEC 61508 and the latest standard for IEC 61511,
The program is included with lots of practice and exercise sessions which are ▪ FTA
very much useful for your better understanding and implementation level at your ▪ Identification safety functions
work
▪ Module 4 - Planning the Safety Instrumented System
Outlines ▪ Overall planning

Day 1:
▪ Implementation of a safety instrumented systems

▪ Module 1 - Introduction to Functional Safety

▪ Safety plan, V&V plan and overall SRS

▪ Accidents in the news

▪ Requirements for suppliers

▪ What is (functional safety?)

▪ Module 5 - Hardware Design

▪ Legal status
▪ De-energize versus energize

▪ Application area
▪ Low Demand

▪ Layers of protection
▪ High Demand

▪ Safety instrumented system

▪ Continuous Mode

▪ Random, common cause, and systematic failures

▪ PFD

▪ History functional safety

▪ PFH
▪ Hardware Fault Tolerance (HFT)
 Process – Functional Safety
Training & Certification
Program
In accordance with IEC 61508 / IEC 61511
Your Training at
TÜV SÜD Academy

▪ Hardware lifecycle ▪ Perform modified (based on IEC 61511) Risk Graph risk reduction
▪ Hardware concepts ▪ Perform LOPA (both standard and modified) and determine SIL levels
▪ Architectural constraints ▪ Define SIF
▪ Measures to control and avoid failures ▪ Develop Safety Requirement Specification
▪ Reliability Analysis ▪ Develop simplified equation worksheets (1001, 1002 and 2002)

Day 3:
▪ Example on RBD

▪ Module 6 – Software Design

▪ Develop verification and validation plan

▪ Software lifecycle
▪ Techniques and measures for each lifecycle phase

▪ Hardware software relationship

▪ Hardware verification lifecycle – here we require hardware practical
using a transmitter, LS and valve/switch
▪ A typical software problem ▪ Software verification lifecycle – we will need LS with program – simple
▪ Safe software algorithm and ask participants to follow application software lifecycle
▪ Three types of software including FAT (this can be done in groups)

▪ Three types of development languages ▪ Hardware and software validation (SAT)

▪ Software tools ▪ Final SRS and SIL report (end of lifecycle)

▪ Module 7 - Certification, Proven In Use and Data Day 5:

▪ Dilemma for end users and system integrators ▪ Module 10 – Maintenance
▪ What is certification? ▪ Perfect Maintenance
▪ What to look for in a certificate? ▪ Perform sensitivities for proof test intervals, DC, ß, better SFF
▪ What is proven in use? ▪ The Impact of Imperfect Proof Test and Maintenance
▪ How to prove “proven in use”? ▪ Diagnostic Coverage
▪ Reliability data sources ▪ Methods for Valve Diagnostics
▪ Module 8 - Using the Safety Instrumented System ▪ Partial Valve Stroke Testing
▪ Installation and commission ▪ Full Valve Stroke Testing
▪ Validation ▪ Module 11 – Engineering and Design
▪ Operation, maintenance, and repair ▪ How to Represent SIF?
▪ Modifications and retrofit ▪ SIL Workshop for Design
▪ Override Procedures ▪ SIL Workshop for Analysis and Verification
▪ Decommissioning ▪ Components selection criteria

Day 4: ▪ Markov-Model

▪ Module 9 – Functional Safety practical issues ▪ Module 12 – Advanced Concepts

▪ How to write SRS ▪ Different Types of Proof Test

▪ SRS Templates ▪ Developing the SRS for BMS

▪ SIL software ▪ Using IEC 61511 concepts for BMS design

 Process – Functional Safety
Training & Certification
Program
In accordance with IEC 61508 / IEC 61511
Your Training at
TÜV SÜD Academy

▪ Design Codes and Standards for Fire and Gas o 2 years is deducted if applicant is M. Tech in engineering or
equivalent
▪ Is FGS (F&G System) a Safety Function? o If candidate has done Doctorate (PhD), it is considered as equivalent
▪ How to use FGS as a Safety Function? of two years’ experience
▪ Multiple safety systems ▪ Two references from Client/Line Manager describing application of
functional safety aspects in projects undertaken by the candidate.
▪ Combined BPCS/SIS Designs
▪ Case Study: Reactor
▪ Must produce evidence that he has participated in at least 2 HAZARD
analysis / SIL determination studies/LOPA studies as a participant and
▪ Case Study: Separator Vessel carried out at least 2 case studies during his work experience. This should
be endorsed by candidate’s organisation and the TÜV SÜD’s subject
Target group matter expert. In instances where the applicant’s employer is not able to
▪ Instrument Engineers endorse the case studies, the same shall be reviewed by TÜV SÜD
Middle East Functional Safety Expert.
▪ Process Engineers
▪ Project managers Exam Format:
85 Questions: Multiple choice questions
▪ System, hardware and software developers
▪ Safety managers Passing Criteria Level 1 (FSEr):
▪ Process Safety Engineer Candidates need to score minimum 50% of the total marks (i.e. 43 out of 85)
to pass this examination.
▪ Safety Engineer
▪ Maintenance Managers Passing Criteria Level 2 (FSP):
Candidates need to score minimum 75% of the total marks (i.e. 64 out of 85)
▪ Manufactures to pass this examination.
Functional Safety Engineer (Fser) Level 01 in accordance with IEC International Certification:
61508/61511
▪ Certificate of successfully passed with the degree examination of
Exam Prerequisites for level 1 (FSEr): “Process - Functional Safety Engineer”.
▪ Having certificate of Bachelor of engineering or equivalent degree ▪ Certificate of successfully passed with the degree examination of
“Process - Functional Safety Professional”.
▪ Minimum of 4 years of experience in process industry (operations,
engineering or consulting)
▪ Candidate holding diploma in engineering shall have minimum of 6 years Sale Modes: Public/ Inhouse Training
of experience Duration: 5 Days
▪ Having attended a professional training course for minimum 24 hours Number of Quizzes: Final Exam (Certified)
covering knowledge equivalent to the scope of certification
Training mode : Instructor Led Training (classroom / virtual)
Functional Safety Professional (FSP) Level 02 in accordance with IEC Skill Level : Fundamental
61508/61511
Language: English
Exam Prerequisites for level 2 (FSP):

▪ Applicant shall have minimum 6 years of relevant industry experience.

▪ Dependent of academic qualifications: