Functional Safety Design, Verification & Validation

Today’s industrial facilities contain an ever-increasing number of equipment hazards. The potential to cause harm to people, equipment, facilities, products, and the environment is real and requires a focused effort to mitigate risks. Regardless of industry, functional safety is critical to success, and preventing worksite incidents is a top priority. LSI’s functional safety team can help.

What is functional safety?

The IEC 61508 defines functional safety as:

  • The detection of a potentially dangerous condition resulting in the activation of a protective or corrective device or mechanism to prevent hazardous events arising or providing mitigation to reduce the consequence of the hazardous event.
  • The part of the overall safety that depends on a system or equipment operating correctly in response to its inputs

All machinery poses hazards to employees and companies. By applying functional safety, you can reduce those hazards by using safety systems and front-end engineering to design those hazards out of the machines. First, an overall assessment of the system is required to determine how the safety-related control systems interact and how the functional safety hardware responds to operator inputs and its environment.

LSI’s Functional Safety Team

LSI brings over 35 years of industrial and safety controls experience. Our team of Functional Safety Professionals (with Functional Safety Professional and Functional Safety Technician certifications) can provide extensive functional safety services for OEMs and end-users, including:

  • Safety system design for:
      • New machines or production lines
  • Existing machine circuit analysis, verification and validation to ensure compliance with applicable requirements

Standards

Maintaining a working understanding of the functional safety standards can be difficult for clients. This can result in an inconsistent and ineffective application of the various standards. LSI is committed to staying abreast of the latest requirements, ensuring clients have access to the expertise they need to navigate new or existing machinery’s safety standards. Our team routinely performs risk assessments, design, circuit analysis, verifications and validations that involve:

  • ISO 13849-1 – Performance Levels (PL)
  • IEC 62061 & 61508 – Safety Integrity Levels (SIL)
  • ISO 13849-2 – Verification and Validation
  • ISO 13850:2015 – Safety of machinery – Emergency stop function – Principles for design
  • NFPA 79 – Electrical Standard – Industrial Machinery Safety

Services and Support

  • Safety system risk assessment per EN/ISO 13849-1 and EN/IEC 62061
        1. Engineering documentation review, configuration, and safety function testing of protection device(s)
        2. Calculation or validation of the determination of failure probability (SIL, PL-calculation)
  • System validation per EN/ISO 13849-2 and EN/IEC 62061
  • Technical support, including safety system installation, commissioning, and validation
  • Equipment design services
  • Four-step safety control design based on:
      1. Risk Assessment
      2. System Design per Risk Assessment Result
      3. Implementation
      4. System Validation to ensure that it meets the design criteria that came out of the Risk Assessment. Certification of equipment of SIL or PL depending on the standard and what came out of risk assessment.

For example: If a risk assessment indicates that the machine needs to meet a performance level of “c” then the design of the system falls under PLc. After the machine is wired, it is first verified and physical components assessed for the physical level of the installed components to determine if the components as a complete system meet the required PLc, then tested for functionality (validation).

Experienced Service Provider

At LSI, we believe that you should always leave work in the same condition as when you arrived. Organizational success is entirely dependent on the safety of personnel, facilities, and the environment. If you want a functional safety team on your side with a solid, proven foundation in process improvement, automation, systems integration, electrical engineering, and manufacturing intelligence, let’s have a conversation. LSI listens.

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