Short definition
Functional safety refers to that part of the overall safety of a system that depends on the correct functioning of safety-related systems. It includes all measures to minimize risk by means of automatic protective devices that automatically switch to a safe state in the event of hazards. IEC 61508 for electrical safety systems and IEC 61511 for the process industry form the normative basis. In membrane filtration systems, functional safety protects against dangerous pressure overshoots, incorrect addition of chemicals or impermissible process conditions.
Security concept
The concept is based on Safety Integrity Levels (SIL 1-4), which define the probability of failure of safety-related functions. A systematic risk analysis (HAZOP, FMEA) identifies hazards and determines the required SIL levels. Safety PLCs with redundant architectures (1oo2, 2oo3) and diagnostic self-monitoring implement the safety functions. Safe sensors and actuators with defined fault reactions complete the safety circuit. The safety lifecycle in accordance with IEC 61511 structures planning, implementation, operation and change management over the entire service life of the system. Regular proof tests validate the functionality.
Areas of application
Functional safety is mandatory for all membrane filtration systems with potential hazards due to pressure, chemicals or product contamination. It ensures the protection of personnel, the environment and the system through reliable automatic reactions to hazardous situations. In regulated industries, proof of functional safety is a prerequisite for approval. Emergency Shutdown Systems (ESD) carry out controlled emergency shutdowns and prevent escalation.
Typical areas of application:
- Pressure limitation for diaphragm protection (SIL 2)
- Emergency stop systems with safe process shutdown
- Leakage detection for toxic or sterile products
- Overfill protection in product tanks
- Secure locking for maintenance access to moving parts
Summary
Functional safety is both a legal obligation and an economic necessity - it prevents accidents, production downtimes and liability risks. Professionally implemented safety concepts reduce insurance premiums and fulfill operator obligations in accordance with BetrSichV and the Machinery Directive. For plant manufacturers and operators, it means legal and planning security as well as proof of due diligence in controlling risks in membrane filtration plants.
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