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Safety Instrumented Systems

I & E -Systems

I&E Systems’ Functional Safety Engineering course provides the underpinning knowledge that is essential for engineers applying safety instrumented systems (SIS) in the process sector.

Target Group

This FS Engineer (TÜV Rheinland) course is aimed specifically at engineers who work for:

  • Engineering companies in the design, installation and commissioning of SIS
  • End-user’ companies who own and/or operate process plant.

It is designed to provide candidates with a holistic view of the entire safety lifecycle from the user’s perspective. It is not intended for engineers involved in the design of the internal hardware for logic solver systems or for the design of field device components by equipment manufacturers.

The course puts a strong emphasis on systematic integrity: avoiding avoidable failures. These failures are primarily due to human error in the specification, design, installation, operation and maintenance of SIS. It also strongly emphasises the importance of user-centred architectural design for safety instrumented systems.


  1. Introduction: What is ‘Functional Safety’?
    1. Regulatory framework
    2. SIFs for risk reduction
    3. Random and systematic failures
  2. Risk management principles, tolerable risk, ALARP.
  3. Standards – history and structure.
  4. The basics of planning and the ‘Safety Life-cycle’.
  5. SIS fundamentals: Conceptual design, risk studies, SIFs and SIF allocation.
  6. Failure modes.
    1. Unrevealed and dangerous
    2. Failure rate data
    3. Hardware fault tolerance
    4. SFF, Diagnostics
  7. SIL Determination.
  8. Safety Requirements Specification.
  9. The importance of deliberate design in SIS architecture.
    1. Separation between layers
    2. Fault tolerance
    3. Design patterns
  10. System detailed design – documentation and traceability.
  11. Quantification of failure rates and verification of compliance to standards.
  12. Systematic capability, techniques and measures.
  13. Human factors.
  14. Functional safety management.
    1. Policy and strategy
    2. Safety management systems
    3. Organisation and responsibilities
    4. Managing competence
    5. Safety Life-cycle planning
    6. Issues management
    7. Supplier management
    8. Records management
    9. Configuration management
  15. Quality management.
  16. Verification and validation – what is the difference?
  17. Operations and maintenance.
    1. Operations planning and management
    2. Proof testing
    3. Maintenance, inspection and testing
    4. Issues and performance management
    5. Modification management
    6. Documentation
  18. Audit and assessment.


The following requirements have to be met qualify for this certificate:

  • A minimum of 3 to 5 years’ experience in the field of functional safety
  • University degree (Master's or Bachelor's degree in Engineering)
  • or equivalent engineer level responsibilities status certified by employer.

Candidates who have not yet gained at least 3 years of experience in functional safety may still participate in the training as well as the exam.

If a candidate passes the exam successfully TÜV Rheinland will hold the results on file until the candidate can demonstrate achieving the necessary 3 years of business experience in the area of functional safety. The FS Engineer certificate will then be issued without the candidate needing to re-take the exam.


The candidate’s knowledge and understanding will be assessed in a 3 part exam:

  • Part 1: 50 Multiple choice questions assessing knowledge and understanding (worth 50%)
  • Part 2: 20 Multiple choice questions assessing understanding the ability to calculate risk reduction requirements and probabilities of failure (worth 20%).
  • Part 3: 10 Written answer questions assessing the candidate’s understanding of functional safety principles and functional safety management (30%).

Candidates may refer to IEC 61511 during the assessment. No other reference materials are allowed.

To complete the exam typically takes around 3 to 4 hours. The pass mark is 75%. Candidates that do not yet meet the grade may have a second attempt within a few weeks’ time.

On successful completion of the exam candidates may apply for the FS Engineer (TÜV Rheinland) certificate.


The course is presented over 3 days and includes classroom exercises. The exam is held on the 4th day, after a tutorial and review session in the morning.

All candidates will be provided with a set of homework exercises to do in their own time. The exercises will be reviewed in interactive tutorial sessions at the beginning of each day of the course.


The cost for each candidate on the full 4 day course is AUD 4,000 +GST.

This includes course materials and the FS Engineer (TÜV Rheinland) certificate - if the exam is passed and requirements fulfilled.

A 10% discount is offered for 3 or more attendees from the same company.

The cost per candidate for the 3 day course without the exam is AUD 3,300 + GST.