Functional Safety Engineering
Mangan Functional Safety Engineering
Functional safety engineering services are a vital aspect of process control safety systems design. These services ensure the safety of personnel, assets, and the environment in industries that handle hazardous materials. Mangan offers decades of expertise in Functional Safety Engineering Services, helping clients develop and maintain comprehensive safety programs that integrate operational and maintenance requirements into the design of mitigation systems.
As a leading provider of Process Safety Consulting, Mangan emphasizes adherence to international standards. A cornerstone of our approach is compliance with ANSI/IEC-61511 ed.2 and ISA 84.00.01—standards that govern the implementation and management of Safety Instrumented Systems (SIS) in the process industry. Our teams, which include highly experienced Functional Safety Consultants, support the full SIS Safety Lifecycle using best practices and advanced software tools, such as Mangan Software Solutions’ TÜV Certified Lifecycle Software SLMTM (www.mangansoftware.com).
Through a combination of Performance-Based and Prescriptive approaches, we help clients meet ANSI/IEC-61511 requirements while aligning with broader Process Safety Management (PSM) frameworks.
This SIL determination—also referred to as a SIL study or assessment—is a key area within Process Safety Engineering. It defines Safety Instrument Functions (SIF) and assigns values for Risk Reduction Factor (RRF) and Mean Time to Fail Spuriously (MTTFS).
Following this, the Conceptual/Process Safety Requirement Specification (SRS) is developed in accordance with ANSI/IEC-61511 and ISA 84.00.01. The SRS outlines functional and safety integrity requirements for each SIS and SIF, including sensors, logic solvers, final elements, and power sources.
Before proceeding with detailed design, Mangan conducts the Stage 1 Functional Safety Assessment (FSA-1) to uncover any systematic design deficiencies and ensure proper assignment of mitigation strategies. This is a core activity in Safety Reliability Engineering, aimed at enhancing early-stage risk control.
Analysis
The initial phase of the Safety Lifecycle involves conducting a thorough Hazard and Risk Assessment, which is fundamental in Chemical Process Safety Engineering. This stage uses tools such as Process Hazard Analysis (PHA) and Layers of Protection Analysis (LOPA) to identify unmitigated risks, assess existing Process Safety Safeguards, and define the necessary Safety Integrity Level (SIL) to bring risk within acceptable corporate thresholds.
Design & Implementation
In the design phase, our Functional Safety Consultants support clients in selecting appropriate certified technologies—sensors, logic solvers, valves, and actuators—that meet the required SILs. Architectural considerations like independence, redundancy, and diversity are addressed, with compliance demonstrated via SIL Verification in accordance with IEC 61508 and IEC 61511.
SIL Verification involves evaluating random hardware failures, systematic capability, common cause failures, and other metrics using methods like Fault Tree Analysis (FTA), Failure Mode and Effect Analysis (FMEA), and Reliability Block Diagrams (RBD). These activities exemplify our commitment to Safety Reliability Engineering as a discipline.
Once the design meets all safety parameters—including PFD, HFT, and SFF—the system is configured and validated through Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT). FSA Stage 2 and FSA Stage 3 are carried out during and after these tests, ensuring the system meets the functional and safety design intent.
Operation and Maintenance
The final phase of the Safety Lifecycle focuses on maintaining the integrity of the system. Our Process Safety Management Consulting services include guidance on scheduled Proof Test Procedures (PTP), performance monitoring, and compliance tracking to ensure all SIFs function reliably over time.
We advise optimizing online versus offline testing strategies and analyzing demand rates or changes in system performance that may impact SIL. Any identified degradation is addressed as outlined in IEC 61511 Clause 17.
Routine Functional Safety Assessments, including FSA Stage 4, are conducted to evaluate operation and maintenance procedures, training, and SIS performance data collection. FSA Stage 5 is performed when modifications are made or prior to SIS decommissioning.
Mangan’s integrated approach brings together decades of practical experience in Chemical Process Safety Engineering, Process Safety Engineering, and Process Safety Management, ensuring that safety systems remain effective and aligned with evolving operational needs.
