Functional safety engineering for hazardous processes and machinery on Australian manufacturing sites. Designed to meet IEC 61511 and IEC 62061 while keeping the system practical to operate.
Functional safety engineering for hazardous processes and machinery on Australian manufacturing sites. Designed to meet IEC 61511 and IEC 62061 while keeping the system practical to operate.
Safety lifecycle engineering to IEC 61511 and AS 62061.
Functional safety starts with clear hazard identification and realistic risk assessment. We support HAZOP, LOPA and SIL determination activities, then convert risk targets into specific safety requirements. Standards including IEC 61511, IEC 62061 and ISO 13849 are applied based on the process and machinery context. Safety instrumented functions, response times, proof test intervals and bypass management rules are defined with operations and maintenance input. For facilities expanding hazardous process areas or introducing new high-energy machinery, this stage is where the compliance position is set. Documented assumptions and risk acceptance criteria reduce ambiguity and improve confidence during audits.
Safety architectures use platforms such as Rockwell GuardLogix, Siemens S7-1500F and compatible safety I/O and instrumentation. We develop cause and effect matrices, shutdown logic, permissives and reset philosophies that align with site procedures and operator training. Testing includes factory verification, loop checks, trip testing and documented evidence of requirement coverage. Where mechanical and electrical scopes intersect, we coordinate closely with OEMs and site teams to confirm final installed behaviour. On a recent emergency shutdown redesign for a utility area where nuisance trips had been causing significant downtime, improving sensing strategy, voting logic and diagnostics maintained safety integrity while availability improved.
Safety is not complete at startup. Lifecycle activities include management of change, periodic proof testing and performance monitoring, all with traceable documentation from requirement specification through design, verification, validation and handover. This includes test records, deviation logs, training notes and maintenance guidance for ongoing compliance. Gap assessments are available for existing systems where documentation or testing history is incomplete. This is common on older plants that have evolved over time without a full lifecycle framework. Structured safety governance is what keeps risk controls effective after the original project team has moved on.
IEC 61511 is focused on process industry safety instrumented systems, while ISO 13849 is commonly applied to machinery safety control systems. The correct standard depends on the application context and risk profile.
Yes. We can perform lifecycle gap assessments, identify high-priority remediation actions and support staged improvements so compliance and risk reduction can be improved without unnecessary full replacement.
Proof tests verify that safety functions still perform as designed. We define realistic intervals, procedures and records so tests can be completed efficiently during planned maintenance windows.
Speak directly with an engineer about scope, timing and technical constraints.
