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Functional Safety for Firing Systems

Firing systems as industrial thermoprocessing equipment and fossile power plants still remain a core element of processual acquiration of heat and energy in General even in times of energy transition. Especiall smaller plants are hereby becoming more significant.

Additional requirements for the reliablity of emissions (e. g. TA air) and energetic optimisations of plants lead to the realisation of the necessary Level of functional safety required PLT-components and Automatisation Systems becoming more powerful and complex.

The European standards for firing systems (essentially the EN 50156-1 „Elektrical Gear of Firing Systems“ and the EN746-2 „Industrial Thermoprocessing Equipment: Safety Requirements for Firing and Final Handling Systems“) have changed dramatically in the past years. From the earlier practiced gear related and qualitative requirements for the instrumentalisation of firing equipment increasingly the adjustment to a specific unit und a hazardrelated Determination of safety relevant requirements is taking place. These requirements can be fulfilled according to the standards for firing equipment either through consideration of relevant product standards for components or through the standards of the IEC 61508/61511 quantitative methods of proof of a sufficient safety Level, respectively a SIL-level of the protection systems.

In practice you will often find a hybrid steering protection system, which fulfills the requirements in relation to functional safety according to relevant product standards (e. g. flame detector or automatic firing device) and partially requirements for functional safety through the proof of safety levels (e. g. O2-surveillance). If the automatic firing device is an Equipment that uses gas turbines or steam turbines, additional Interfaces to other regulatory frameworks such as the machinery directive and the standards for the requirements for the functional safety of machines (such as the EN62061 or the ISO13849) or national papers like VDMA data sheets are possible.

Further problems arise from the usage of current frameworks when adjusting or changing existing devices, which gear with protection Systems does oftentimes not adhere to the current requirements of the standards.

A sufficient consideration of all requirements from the different regulatory frameworks is posing inreasing challenges for executives, manufacturers, and operators.

To solve these challenging tasks TÜV NORD can suport you with interdisciplinary teams of experienced professionals of the different disciplines, even of functional safety, to guarantee a framework conformitive interpretation, evaluation and change management of your facilities. During the phase of a life cycle safety devices have numerous requirements for the realisation of sufficient functional safety. In order to enable this over the entire course of a life cycle different requirements are made in the corresponding regulatory frameworks, which are to be observed in a lagally binding facility life cycle during all phases of the life cycle. This beginns with requirements at the underlying risk assessments, the specification of the safety installments, the design and the planning, installation, testing before commissioning, the operation, the plant maintenance and changes as well as finally the decommissioning of the safety devices.

TUV NORD has been accompanying their customers for 150 years throughout Germany and in more than 70 countries as a reliable and independent partners in all matters of facility safety. We are well-structured, conscious of costs and deadlines, and we offer to our planners and operators of facilities a solution-oriented service portfolio.

Our service portfolio consists of:

Trainings & Coachings

  • E-learning for functional safety in the process industry free of charge
  • Trainings and workshops regarding the IEC 61511
  • Coaching for the composition or check of the safety Management system

Pre and Concept Assessments (e.g. TÜV NORD SIL approved)

  • Moderation and documentation of the hazard and risk analysis
  • Testing of the safety specifications (hardware and software)
  • Structural and quantitative proof of SIL and its verification
  • Preparation, monitoring and documentation of the acceptances of contract works (e.g. FAT)

Legally binding Assessments

  • Assessments according to §14 BetrSichV (Assessment of work equipment)
  • Assessments according to §15 BetrSichV (Assessment before commissioning and after changes) 
  • Assessments according to §16 and §19(5) BetrSichV (recurring assessments and after case of damage) 
  • Assessments according to §29a of the federal emission law

Coaching Services regarding the Operation of Facilities

  • Coaching regarding the collection of disturbance data as well as the assessment and coaching for proof of Betriebsbewährung
  • Coaching regarding change management
  • Audits regarding functional safety assessment of operators

If you have further questions and to compose a Service Portfolio that is custom-fit to your Needs, you may contact us at any time. We are looking forward to hearing from you and working together with you successfully on your projects!