Functional Safety


The safe design of plant / machinery is evolving as better ways of ensuring safety are developed. For many years, the main focus of safety control systems
was the structure, through the Category or “CAT” system as outlined in AS4024.1501 as well as the now superseded EN 954. While using well tried
components was recognised as being useful, designs for control systems focused
on the structure with less investment in regards to the reliability of

The chemical process industry took a different path as it typically had significant risks to mitigate. It focused on the reliability of equipment and then considered the system’s structure. It did this through the implementation of AS/IEC 61511 its own localised version of IEC/AS 61508 Some machines do have significant risks and Functional Safety for Machinery is used to manage these pieces of plant.

While not all machinery is as complex and can expose many people to potential high risks as a chemical plant, understanding and possibly taking a functional safety approach, for example through AS4024.1503 (EN13849) or AS/IEC 62061 to your machinery can be useful. Some equipment, for example mine winding systems require a functional safety approach as it is seen as best practice. This is highlighted through the NSW Government’s Department of Industry Resources and Energy’s Mining Design Guidelines, specifically 33.6 Mine Winder Control Systems.

Electro 80 has a team of TUV Rheinland functional safety engineers who can work with you to develop a safety control system for your high risk plant, to ensure that the risk is controlled. We can also assist your company determine the best approach to take. Equipment that can benefit from a functional safety approach to a safety control system includes:

  • Mine winders
  • Stacker / Reclaimers
  • Amusement rides
  • Robots
  • Machinery being sold overseas especially, Europe
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