Functional Safety Audits
We run the IEC 61511 lifecycle audit and verify safety system competency so your SIL claim becomes defensible
Functional Safety
Audits
A functional safety audit is the independent examination that converts a claimed safety integrity level into a defensible one. IEC 61511 mandates functional safety assessment at defined lifecycle stages because the dominant threat to a safety instrumented system is not random hardware failure but systematic error introduced silently during specification, design, installation and operation. Our audit interrogates that lifecycle from end to end. We check whether the safety requirements specification traces back to the hazard and risk analysis, whether the realised design and proof test regime actually deliver the target probability of failure on demand, and whether the organisation managing the system holds the competence and independence that IEC 61511 Clause 5 demands. Conducted against TÜV and exida criteria across functional safety assessment stages one to five, the audit exposes the gap between paper compliance and live integrity before that gap is found by a demand the safety function cannot meet.
Functional Safety Audits workflow
Define FSA scope per IEC 61511 Phase 15, Stage 1 (after PHA/SIL allocation), Stage 2 (after design), Stage 3 (after installation/commissioning), Stage 4 (operational, every 3, 5 years), Stage 5 (after modification), align with TÜV / exida audit protocol.
Review Functional Safety Management plan per IEC 61511 Cl.5, roles, responsibilities, competency framework, verify FSE / FSEng / FSP competency records per TÜV / exida certification, review training records and CPD evidence.
Sample evidence across PHA records, SIL allocation, SRS, design, FMEDA, PFD calculations, proof test records, MOC records, incident investigation, verify chain of traceability from hazard to SIF to verification.
Observe SIS in operation, alarm response, bypass authorisation, proof test execution, conduct site walk down for label verification, accessibility for testing, environmental conditions, interview operators, technicians, and engineers.
Categorise findings per IEC 61511 audit protocol, Critical (lifecycle gap), Major (process gap), Minor (improvement), assign risk rank and target close out date, align with site MOC procedure for corrective action tracking.
Issue FSA report with executive summary, findings register, evidence pack, and improvement roadmap, conduct close out verification for previous audit findings, integrate with site management review and HSE leadership reporting.
Every deliverable from basis to handover
Complete Functional Safety Audits scope covering every calculation, drawing, specification, and construction support activity.
Outcomes of Functional Safety Audits
- We verify that safety function integrity is maintained across the lifecycle
- We identify weaknesses in the safety system programme
- We sharpen management of change controls
- We anchor operational integrity
- We keep you aligned with the IEC 61511 audit requirements
- We support TÜV and exida external audit
- We document the competency of the functional safety manager and system manager
- We give you documentation that withstands regulator scrutiny of the safety system
- We identify gaps in proof test execution
- We tighten management of change for safety system modifications
- We improve cross function dialogue on the safety system
- We build an enduring functional safety culture
- We help you avoid safety system rework caused by compliance gaps
- We reduce the cost of failing a safety system audit
- We support your insurance dialogue
- We optimise safety system lifecycle investment
Codes & standards we work to
Triggers that signal the need
Where Functional Safety Audits applies
Wellheads, separators, gas compression, FPSO topsides, produced water systems.
Distillation columns, reactors, heat exchangers, storage spheres, LPG handling.
Cryogenic exchangers, liquefaction trains, BOG compressors, storage and sendout.
Reactive systems, batch reactors, solvent handling, runaway reaction scenarios.
Boilers, HRSGs, steam headers, hydrogen systems, ammonia SCR units.
Sterile vessels, CIP/SIP, pressure fermenters, solvent recovery, spray dryers.
Tangible deliverables
- Functional safety assessment reports for stages one, two, three and four
- Competency assessment
- Document trail review
- Non conformance register
- Improvement action plan
- Annual functional safety assessment programme
Ready to start your project?
Speak with our team to scope an engagement tailored to your facility, regulatory context, and lifecycle stage.