Managing Risk Across the Entire Lifecycle

Functional safety in process industries is governed by the international standard IEC 61511, which sets out the requirements for managing safety systems throughout their entire lifecycle, from hazard identification and SIL assessment to design, implementation, operation, and ongoing maintenance. At Safety Solutions, our TÜV-certified functional safety consultants have extensive experience applying IEC 61511 across diverse hazardous industry sectors, helping organisations achieve compliance, reduce risk, and ensure the integrity of their safety instrumented system. Our approach can integrates both SIL verification with practical, hands-on functional safety training to give you both the technical assurance and team capability needed for long-term safety performance. 

The Problem: Gaps in Safety and Knowledge

In industries such as oil and gas, manufacturing, chemicals, and renewable energy, safety-critical systems must meet strict integrity levels and be managed through a clearly defined lifecycle. Yet, many organisations face two persistent challenges: 

  1. Incomplete SIL verification – Systems may not meet the required Safety Integrity Level, leaving unacceptable risk in place. 
  2. Limited functional safety lifecycle knowledge – Teams lack the skills to manage safety effectively from design through to decommissioning. 
Functional Safety

The Risks of Not Addressing These Gaps

  • Safety Incidents – Without proper verification, safety functions may fail during critical moments, leading to incidents, injuries, or fatalities. 
  • Regulatory Non-Compliance – Failing to meet IEC 61511 requirements can result in enforcement action, fines, and project delays. 
  • Operational Downtime – Inadequately managed systems are more prone to breakdowns and unplanned shutdowns. 
  • Reputational Damage – A single incident can erode trust with regulators, clients, and the public. 
  • Higher Costs – Poor safety management leads to inefficiencies, reactive maintenance, and costly incident recovery.

Our Integrated Solution

SIL Verification

We assess your safety-related systems to confirm that they meet the target Safety Integrity Level. Using proven tools like SIL Solver and ExSILentia, our consultants verify compliance, identify gaps, and provide clear recommendations for corrective action. 

Outcome: Verified compliance with IEC 61511 requirements, reduced operational risk, and improved system reliability. 

Functional Safety Training

We provide targeted training for engineers, operators, and maintainers involved in the design, operation, and maintenance of safety-instrumented functions. This 1-day course is ideal for professionals in manufacturing, chemicals, power, and other process industries who need a practical introduction to functional safety concepts. The programme covers the fundamentals of the

IEC 61511 and IEC 61508 standards, which govern the design, operation, and maintenance of Safety Instrumented Systems (SIS). Participants will learn how to navigate the functional safety from concept and design through to operation, maintenance, and modification and understand their role in each stage. 

Outcome: A confident, capable workforce with a solid grasp of functional safety principles, able to maintain compliance and make informed safety decisions in real-world situations. 

For those wanting to take their learning further, this course also offers an optional 3-hour one-on-one. Support Package with a senior Safety Solutions consultant, providing personalised guidance to strengthen skills and apply knowledge directly to workplace challenges. 

Expertise Across the IEC 61511 Lifecycle

Our TÜV-certified functional safety consultants have decades of combined experience in: 

  • Lifecycle Management Plans
    Hazard Identification (HAZID) – Facilitating hundreds of reviews and training leaders and participants internationally.
  • Safety Requirements Specification (SRS) – Creating robust, compliant specifications and company standards. 
  • System Design & Verification – Using advanced software to design, verify, and document compliance. 
  • Operation & Maintenance – Developing operational procedures such as proof testing and bypass management. 
  • Management of Change (MoC) – Designing systems to safely manage plant and software changes.
  • SIL Determination & Risk Assessment– Applying LOPA and Risk Graph techniques to hundreds of scenarios. Our consultant have also delivered extensive LOPA and SIL training sessions across New Zealand, Australia and internationally.
  • Functional Safety Audits – From individual SIL function assessments to full management system reviews.

Measurable Benefits

  • Fewer Incidents – Verified systems reduce the risk of failure during critical operations. 
  • Regulatory Assurance – Full compliance with IEC 61511 and other applicable standards. 
  • Improved Uptime – Well-managed systems mean fewer unplanned outages. 
  • Stronger Safety Culture – Skilled, trained personnel who actively manage functional safety.

Why Choose Safety Solutions?

Be confident in your choice of partner for process safety. CONTACT SAFETY SOLUTIONS to work with certified experts who deliver practical, reliable outcomes tailored to your business. 

  • Certified Specialists – Our consultants are TÜV-certified and highly experienced across multiple sectors. 
  • Industry-Leading Tools – We use advanced software and proven methodologies for accuracy and efficiency. 
  • Tailored Approach – We adapt our process to your specific operations, industry, and compliance needs. 
  • End-to-End Support – From initial asses
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