Safety Instrumented Systems — FS Technician

TinoVC DMCC - TÜV Rheinland

This FS Technician training course is designed for professionals in the process industry who seek to enhance their knowledge and competency in Functional Safety according to IEC 61511. The course provides in-depth training on Safety Instrumented Systems (SIS), their design, implementation, and lifecycle management, with the prime focus on Operations and Maintenance activities. Participants will also prepare for the FS Technician (TÜV Rheinland) SIS certification exam.

Course Objectives

  • Understanding Functional Safety principles based on IEC 61511.
  • Understanding the quality aspects and importance of Functional Safety Management (FSM), FSA (Functional Safety Assessment), and FS Audits.
  • Learning the complete SIS lifecycle, including risk assessment, design, implementation, validation, operations, maintenance, modifications & decommisioning activities workflow.
  • Recognizing techniques such as HAZOP, LOPA, Risk Graph, and Fault Tree Analysis and understanding why these are used.
  • Recognizing Safety Integrity Levels (SIL) and risk reduction measures.
  • Learning what and how bypasses and compensating measures are used.
  • Understanding the dilemma between safety availability versus production availability.
  • Learning what and how proof-test intervals, coverage and consistency requirements are used.
  • Understanding the management of change and the importance of FS assessment stage 5 before starting a modification on any SIF/SIS.

Target Group

  • Process safety engineers
  • Maintenance personnel and Technicians
  • Instrumentation & control engineers
  • Functional safety professionals
  • SIS designers & operators
  • Risk assessment practitioners

Agenda

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Day 1: Introduction & Risk Assessment

Module 01: Introduction to Functional Safety

  • Overview of Functional Safety & IEC 61511
  • Modern history of industrial disasters
  • What is safety? Layers of Protection Analysis (LOPA)
  • Key SIS definitions: SIS, SIL, SIF
  • Safety system failures and functional safety principles

Module 02: Functional Safety Lifecycle & Management

  • IEC 61508/61511 Lifecycle concept
  • Functional Safety Management (FSM) & Competency
  • FS Assessment & FS Audits
  • SIS configuration and lifecycle planning
  • Compliance, verification, and documentation requirements

Module 03: Process Hazard & Risk Assessment

  • Hazard & Risk definitions
  • Tolerable risk and ALARP
  • Risk management techniques: HAZOP, FTA, Risk Matrix & Risk Graph
  • Security Risk Assessment considerations

Module 04: Safety Function Allocation & SIL Selection

  • Layer Of Protection Analysis (LOPA)
  • Typical IPL characteristics
  • SIF operating modes and SIL requirements

Day 2: SIS Design, Implementation, Operations & Maintenance

Module 05: Safety Requirements Specifications & Design

  • Safety instrumented Function (SIF) descriptions
  • 29 items that a SIF shall include and describe according to IEC61511
  • Mean Time to Restoration (MTTR), Mean Repair Time (MRT)

Module 06: SIS Engineering & Factory Acceptance Testing (FAT)

  • General requirements, hardware selection, and BPCS-SIS integration challenges
  • Functional Safety Manual & hardware failure concepts
  • Voting configurations (MooN, HFT, Route 2H vs Route 1H)
  • Prior Use & Proven in Use failure data
  • Systematic Capabilities (SC)
  • Maintenance & testing requirements

Module 07: Installation, Commissioning & Validation

  • Installation planning & documentation
  • Site Acceptance Testing (SAT) procedures
  • Validation & operational readiness checks

Module 08: Operation, Maintenance & Proof Testing

  • Operational best practices & periodic testing
  • Bypass management & proof test procedures
  • Operator & maintenance training requirements
  • Inspection, discrepancy management, and documentation

Module 09: Modification & Decommissioning

  • Management of Change (MoC) process
  • Differences between change vs a modification
  • Functional Safety Assessment Stage 05 (FSA) considerations
  • Decommissioning procedures & authorization

Exam

Prerequisite to do the examination is that the applicant has to attend TVC Functional Safety Services FZ LLC – training course: “Functional Safety Technician (TÜV Rheinland) SIS” and be eligible according the participants eligibility requirements (see below).

  • Closed book exam- maximum 3 hours on the third day morning consisting of two parts:
    - Part 01 = 30 multiple-choice questions (A-B-C-D) – 1 mark each question. Only 1 answer is the most complete and correct answer, no negative marks for wrong answers
    - Part 02 = 10 open questions – 3 marks each question

  • The exam pass score criterion is 75%
  • Successful candidates will receive an internationally recognized Functional Safety Technician SIS certificate issued by TÜV Rheinland.

Participants Eligibility Requirements

  • Minimum 2 years of experience in Functional Safety or relevant field
  • Technical qualification in a relevant discipline or equivalent technician-level responsibilities as confirmed by the employer
  • If no technical qualification, a reference letter from the employer is required

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