Functional safety • SIL / PL • SIS design and lifecycle

Functional Safety Course

Practical training on functional safety requirements, safety system analysis, SIS design and operation according to IEC 61508, IEC 61511 and ISO 13849-1.

The course is delivered by a certified Functional Safety Specialist with recognised certification and many years of practical field experience in Europe.

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Practical Functional Safety Training for Industry

Functional safety is essential wherever control systems, safety functions or protective measures are used to reduce risk. A safety system must not only be correctly designed, but also properly analysed, verified, validated, operated and maintained throughout its lifecycle.

This course provides a structured and practical understanding of functional safety principles for machinery, process plants, automation systems and safety-related control systems.

1 Hazard analysis Identify hazardous events, initiating causes and required risk reduction.

2 Safety requirements Define what the safety function must do and under which conditions.

3 Design and engineering Select architecture, diagnostics, redundancy and safe failure behaviour.

4 Verification Confirm design evidence, calculations, assumptions and documentation.

5 Validation Test that the safety function performs correctly in real conditions.

6 Operation Maintain performance through testing, maintenance and change control.

Standards Covered

The course explains how the major functional safety standards relate to process safety, machinery safety and programmable safety-related systems.

IEC 61508

The fundamental standard for functional safety of electrical, electronic and programmable electronic safety-related systems. Participants learn the safety lifecycle, SIL concepts, hardware reliability, systematic capability and verification principles.

IEC 61511

The process industry standard for Safety Instrumented Systems. The course covers SIL determination, SIS design, SRS development, validation, proof testing, operation and maintenance.

ISO 13849-1

The machinery safety standard for safety-related parts of control systems. Participants learn Performance Level, Category, MTTFd, DC, CCF and validation logic for machine safety functions.

Core Course Topics

Each topic is presented with practical examples so participants understand how functional safety decisions affect real systems, documentation and operation.

Topic 01

Functional Safety Fundamentals

Introduction to functional safety, risk reduction, safety functions, safety integrity, failure behaviour and the difference between process safety, machine safety and control system safety.

Training focus: Why functional safety is required and how it fits into risk assessment and CE conformity.

Topic 02

Safety Lifecycle

Functional safety is managed through concept, hazard analysis, specification, design, verification, validation, operation, maintenance, modification and decommissioning.

Training focus: How to structure safety activities, responsibilities and documentation across the lifecycle.

Topic 03

Hazard and Risk Analysis

Participants learn how hazards are identified, risks are evaluated and required risk reduction is assigned to safety functions.

Training focus: Practical methods for analysing hazardous events, initiating causes, consequences and safeguards.

Topic 04

SIL and Performance Level Determination

The course explains how SIL and PL requirements are determined based on risk reduction needs and applicable standards.

Training focus: SIL allocation for process safety and Performance Level determination for machinery safety functions.

Topic 05

Safety Requirements Specification

A safety function must be clearly specified before it can be designed. The Safety Requirements Specification defines what the safety function must do and under which conditions.

Training focus: How to write clear, testable and complete safety requirements for SIS and safety-related control systems.

Topic 06

SIS Design and Engineering

Participants learn sensor selection, logic solver architecture, final elements, redundancy, diagnostics, proof testing and safe failure behaviour.

Training focus: How to design Safety Instrumented Systems that meet the required SIL and operational requirements.

Topic 07

Safety-Related Control Systems for Machinery

The course covers ISO 13849-1 concepts such as safety functions, categories, Performance Level, diagnostic coverage, MTTFd and common cause failure.

Training focus: Practical application for interlocks, guards, emergency stops and protective devices.

Topic 08

Verification and Validation

Safety systems must be verified against design requirements and validated against intended safety functions before operation.

Training focus: Test planning, validation procedures, documentation and evidence required to demonstrate compliance.

Topic 09

Operation, Maintenance and Proof Testing

Functional safety does not end after commissioning. Safety systems must be maintained, periodically tested and managed during operation.

Training focus: Proof test intervals, bypass management, maintenance procedures and lifecycle documentation.

Topic 10

Modifications and Management of Change

Changes to software, sensors, logic, final elements, operating conditions or process parameters can affect functional safety.

Training focus: How to assess modifications, update documentation and maintain compliance during the lifecycle.

SIS Design and Operation

Participants learn how a Safety Instrumented Function is structured, specified, designed, verified, validated and maintained.

Sensor

Detects the hazardous condition or process deviation.

→

Logic Solver

Processes the signal and initiates the safety action.

→

Final Element

Brings the system to a defined safe state.

Safety System Analysis Covered

Safety function definition: what must be detected, decided and brought to a safe state

SIL / PL target setting based on required risk reduction

Architecture review of sensors, logic solvers, final elements, redundancy and diagnostics

Failure analysis including dangerous failures, safe failures and common cause failures

Proof test strategy, intervals, coverage, procedures and responsibilities

Validation planning under real operating conditions

Who Should Attend?

The course is suitable for engineering, safety, compliance, operations and management roles responsible for safety systems or safety-related control functions.

Engineering Teams

Functional safety engineers, automation engineers, control engineers, electrical engineers and instrumentation specialists.

Safety and Compliance

Process safety engineers, machine safety specialists, CE professionals and compliance teams.

Project and Operations

Project engineers, project managers, maintenance personnel, operations teams and engineering managers.

What Participants Will Be Able to Do

Interpret Functional Safety Requirements

Understand how IEC 61508, IEC 61511 and ISO 13849-1 apply to different industries, systems and safety functions.

Define Safety Functions

Translate hazards and risk reduction needs into clear safety functions and measurable safety requirements.

Support SIS and SRP/CS Design

Contribute to the design of Safety Instrumented Systems and safety-related parts of control systems.

Manage Safety Lifecycle Activities

Understand verification, validation, operation, maintenance, proof testing and modification control.

Course Materials

Functional safety lifecycle overview

IEC 61508, IEC 61511 and ISO 13849-1 comparison

SIL and PL determination examples

Safety Requirements Specification guidance

SIS design and operation checklist

Proof testing and validation examples

Management of change checklist

Practical case studies and exercises

Delivered by Experienced Functional Safety Specialists

The course is delivered by a Functional Safety Specialist with certification from recognised organisations such as exida and extensive practical field experience in Europe.

The training combines standard requirements with real engineering examples from industrial automation, process safety, machinery safety and safety system implementation.

The course can be delivered in English, German or additional languages upon request.

Train Your Team in Functional Safety

Whether your organisation works with Safety Instrumented Systems, machinery safety functions or complex automation systems, this course provides a practical foundation for compliant and reliable functional safety implementation.

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