Functional Safety

When uptime, duty of care, and compliance converge, our TÜV certified Functional Safety team closes the loop, from initial risk assessment through validation and lifetime support. Because we design and build machinery ourselves, our safety advice is grounded in real world manufacturing constraints, not just textbooks.

At Marand, our comprehensive 4-step lifecycle ensures robust, certified safety solutions at every stage.

1. Concepts and Studies – Prefeasibility, high level risk scans, concept safety design.
   Deliverables: Preliminary hazard register, Safety Integrity Level (SIL) / Performance Level (PL) target matrix
2. Analysis and Specification – Hazard and Operability (HAZOP) study / Level Of Protection Level (LOPA) facilitation, So Far As Is Reasonably Practical (SFAIRP) / As Low As Reasonably Practical (ALARP) verification, Safety Requirements Specification (SRS).
   Deliverables: Full risk assessment report, SRS with allocation
3. Design, Build and Verify – Electrical, mechanical & software safety design (IEC 61508 / ISO 13849), SISTEMA / PAScal verification, Factory Acceptance Testing (FAT).
   Deliverables: Verified safety architecture, proof test procedures
4. Validate & Operate – Site Acceptance Testing (SAT), performance testing, proof test execution, training, change management supports.
   Deliverables: Validation dossier, operator & maintenance manuals

We offer a unique and valuable service bringing the perspective of an OEM with decades of experience to deliver a practical approach to functional safety:

• OEM + TÜV Certification – rare combination of hands on build experience and third party endorsement
• Integrated Controls & Mechanical Expertise – single team covers electrical, hydraulic, pneumatic and software safeguards
• Lifecycle Mindset – we stay engaged for modifications, upgrades and periodic proof testing

Marand applies our experience with leading international and Australian standards, backed by advanced software tools, to ensure safety is designed, verified, and compliant from the ground up. These include:

• International – IEC 61508, IEC 62061, ISO 13849, IEC 61511.
• Australia/New Zealand – AS 4024 (machinery), AS/NZS 3000 (wiring rules).
• Software & Verification – SISTEMA, PILZ PAScal, Reliability Workbench, PHA Pro.

We offer flexible safety engagement models tailored to your project stage, delivering clear insights, practical upgrades, and expert support from concept to commissioning.

• Independent risk assessment – New plant cap ex approval or pre audit check.
  Delivers: Gap analysis, recommended mitigations, budget estimate.
• Safety upgrade package – Brown field machinery needing compliance lift.
  Delivers: Scope, design, parts kit, integration & validation.
• Embedded safety lead – Major green field project with evolving hazards.
  Delivers: Ongoing SRS updates, design reviews, site support.

For A Safety Consultation, or Sample SRS Extract, Contact | Marand