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FUNCTIONAL SAFETY IN PROGRAMMABLE LOGIC CONTROLLERS

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 Academic Research and Reviews in Engineering Sciences

CHAPTER 30

FUNCTIONAL SAFETY IN
PROGRAMMABLE LOGIC
CONTROLLERS

Assist. Prof. Dilşad ENGİN1

1 Ege Üniversitesi Ege Meslek Yüksekokulu Elektronik ve Otomasyon Bölümü

ORCID: 0000-0003-0159-275X
537
 Assist. Prof. Dilşad ENGİN

1. Introduction
The integration of digitalization and the Internet of Things (IoT) into industrial
applications has been facilitated using general-purpose software and
communication of devices through industrial networks in the age of Industry 4.0.
This remarkable potential for improved efficiency and connectivity may
introduce significant risks that must be carefully considered. The critical factors
in conventional information technologies are safety, security, reliability, and
efficiency. The reliance on digital technologies and IoT in industrial sites
necessitates robustness in safety measures. The increased connectivity and data
exchange in Industry 4.0 introduce new cybersecurity challenges. Protecting
industrial systems from cyber-attack threats can be accomplished by preventing
unauthorized access, data breaches, and potential disruptions. Azarmipour et al.
(2019) proposes a new architecture for PLCs, referred as “PLC 4.0”, which
specifies a platform that allows connectivity with the cloud systems regarding the
security issues (Azarmipour et al., 2019). This architecture developed for
controllers improves the capabilities of PLCs including scalability, and
Communication Quality of Service. When connected to higher automation layers,
the PLC adjusts to the system constraints or modifications associated with failure
and safety.
Industrial processes often operate in mission-critical environments.
Consequently, the reliability of digital systems, including sensors, controllers,
and communication networks is crucial in maintaining uninterrupted and efficient
production. Digitalization and IoT offer opportunities for increased efficiency,
but careful design and implementation are required to optimize industrial
processes without compromising functional safety and reliability (Da
Anunciaçao et al., 2022).
As a result of industrial developments, specifically Industry 4.0, the
complexity and digitalization of industrial control systems have increased, and
their integration into the internet, including access to IoT systems, has also
become important (Sehr et al., 2021). Due to interconnectivity of programmable
logic controllers (PLCs) with these systems make them vulnerable to the cyber-
attacks (Hajda et al., 2021). The development of PLC hardware technology has
led them to be a component of complex systems control, but hardware and
software safety must be considered in conjunction including the safe and secure
communication.
In the field of factory automation, big data is systematically collected from
numerous sensors, facilitating the automated control of many actuators. The big

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data generated can be stored in the cloud and visualized on a specialized Internet
of Things (IoT) platform, accessible for monitoring by authorized technical staff.
With the prevalence of data-driven automation, the need for comprehensive data
monitoring has become increasingly evident. This requirement arises from the
request to not only collect extensive amounts of data but also to actively oversee
and analyze this information to ensure optimal performance and responsiveness
in the automated processes. Monitoring plays a fundamental role in maintaining
efficiency, identifying potential issues to keep the required level of safety, and
facilitating real-time adjustments, contributing to the seamless functioning of
automated systems in a factory. Within the framework of Industry 4.0, the IoT
system and optimization algorithms have the flexibility to be customized for
distinctive machinery and processes. This customization is particularly valuable
in applications involving distributed control systems and unmanned autonomous
environments. The efficacy of the distributed systems relies on the seamless
exchange of data and the control of final elements, which is facilitated using
industrial communication protocols between the devices and the central control
computer. This advancement in industrial control technology enhances
efficiency, responsiveness, and the overall ability to manage complex processes.
In the modern industrial landscape, there has been a significant shift from
traditional techniques of measurement and control to a more advanced
methodology that incorporates the acquisition, supervision, and regulation of data
via computers and PLCs. Distributed control architecture systems have emerged
as a prominent solution, enabling the gathering and processing of data from
remote locations via a central control computer where PLCs are the control units
in the field.
2. Programmable Logic Controllers
Programmable Logic Controller is an industrial computer for controlling
industrial processes and machinery in factory automation. They are designed to
control and monitor production lines, machinery, and processes on the factory
floor from handling simple tasks such as start/stop actions, temperature regulation
to production line controls and managing complex sequences of operations by
integration with sensors and actuators. PLCs continuously read the state of input
devices and constructed on a user program, write to the state of output devices in
real-time. This is critical in assembly lines and robotic systems applications,
where precise timing and synchronization are essential.
The significant advantage in using a PLC is the ability to flexibly change and
replicate the operation or process by adapting to changing production

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 Assist. Prof. Dilşad ENGİN

requirements and different manufacturing processes while collecting and

communicating vital information. Modularization in process industries and
discrete control systems necessitates more flexible safety systems. In these
systems only one safety system cannot cover the requirements of entire plant or
manufacturing system (Klose et al., 2020), (Klose et al., 2021). To ensure flexible
functional safety issues, Klose et al. (2020) propose intramodular and
intermodular functional safety concepts to design a system with minimum harm,
and to design smaller independent safety systems which will be coordinated by a
superordinate safety system.
PLCs can communicate with other automation components, including
Human-Machine Interface (HMI) devices and Supervisory Control And Data
Acquisition (SCADA) systems. This communication facilitates data exchange,
monitoring, and control at various stages of the manufacturing process. They are
designed to withstand harsh industrial environments, making them more rugged
and durable than general-purpose computers. They ensure reliable operation in
conditions involving temperature variations, humidity, vibration, and electrical
noise. PLCs also include diagnostic features that identify faults or anomalies in
the system, enabling quick troubleshooting and reducing downtime. This
contributes to increased overall efficiency in manufacturing operations.
PLCs are a reliable platform for factory automation and industrial process
design, based on the IEC 61131 standard which provides the nomenclature used
in this context and describes the major functional features of programmable
controller systems. The standard covers programming style (IEC 61131-3),
networking style (IEC 61131-5), and physical interconnects (IEC 61131-2),
procedures for the application and execution of the programming languages
outlined in IEC 61131-3 (IEC 61131-8) which together enable the smooth
integration of components in complex automation systems, ensuring consistent
performance (Sehr et al., 2021). The technical revision IEC 61131-1:2003 applies
to PLCs and related peripherals, such as programming and debugging tools and
HMIs. As PLCs are modules, IEC 61131-1 does not cover safety concerns for the
complete automation system. Part 1 addresses PLC safety in relation to electric
shock and fire threats, electrical interference immunity, and error detection of the
PLC operating in the system (IEC 61131:2022 SER, 2023).
3. Functional Safety and its Importance in Automation Systems
The significance of functional safety is increasing due to the aim of reducing
the threats and risks associated with errors or failures in manufacturing processes,
ensuring the safety of individuals, machinery, and the environment. Engineering

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a system and obtaining certification under functional safety standards like IEC
61508 requires a significant commitment of time and effort. This not only
increases costs but also introduces the risk of significant delays in product release
when compared to the development of solutions that do not prioritize safety
measures. Industries must navigate a delicate balance between enhanced safety
and the associated investment of resources in their pursuit of functional safety.
In a rapidly evolving technology-focused world, the importance of functional
safety is essential. Functional safety is a crucial engineering aspect that
concentrates on guaranteeing safe, reliable, and consistent system functionality,
in consequences where failure could lead harm to the individuals, damage to the
machinery and the environment. The intersection of advanced technology and the
challenging condition in hazardous environments requires a dedicated focus on
functional safety.
Functional safety can be defined as the capability of a system to execute its
proposed function while reducing the risk of causing harm. This concept assumes
particular significance in industries and manufacturing, where the breakdown of
a system has the potential to result in severe consequences. Functional safety
identifies hazardous failures that may result in significant consequences such as
human injury, death, or equipment damage. The maximum frequency targets are
established for each failure mode. Equipment whose malfunction can contribute
to these identified hazards is typically labeled as 'safety related.' The maximum
allowable failure rate for each hazard determines an integrity target for the
associated equipment, depending on its contribution to the specific hazard. These
integrity targets are referred to as 'safety-integrity levels' (SILs) (Smith &
Simpson, 2004) which show the risk reduction level specified by a security
function.
SIL is a measure to assess the performance of a safety system. It is quantified
by the Probability of Failure on Demand (PFD), which accurately depicts the
probability of failure rather than proper performance. There are four discrete
levels of integrity: SIL 1, SIL 2, SIL 3, and SIL 4. The ascending order of SIL
levels corresponds to an elevated safety level. However, as the SIL level
increases, there is a parallel rise in installation and maintenance costs, as well as
an increase in the complexity of the system. Therefore, SIL 4 systems are not
financially advantageous to implement.
The first step in determining the required SIL level for a system is to conduct
a Process Hazard Analysis (PHA) where the functional safety requirements and
the reasonable risk level are identified. Once every risk reduction besides

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modification impact from all layers of protection have been considered, a risk
reduction factor (RRF) can be determined, and the need for a Safety Instrumented
System (SIS)/SIL requirement can be calculated.
The Safety Instrumented Function (SIF) is a safety function that is designed
to reach or maintain a safe state with a definite safety level. A SIF can be a
'protection function', which maintains a safe state in occurrence of a hazardous
event; a 'mitigation function', which achieves a safe state after the occurrence of
a hazard; or a 'control function', which maintains a safe state during normal
operation.
The selection of the appropriate SIL level must be performed with care due to
the significant cost increase associated with achieving higher SIS/SIL levels. In
the process industry, companies will approve SIS designs up to SIL 2. However,
if a PHA indicates a need for a SIL 3 SIS, the owners will require the engineering
company to redesign the process to reduce the intrinsic process risk. Considering
a thorough understanding of safety requirements, such as hardware, systematic,
and software safety integrity, it is essential to accurately determine SIL for the
specific sector.
Functional safety in Programmable Logic Controllers (PLCs) is essential to
ensure that these devices operate safely, particularly in environments where they
control critical processes or machinery. PLCs intended for use in safety-critical
applications are designed and manufactured following international safety
standards to confirm their ability to manage potentially dangerous situations. The
safety standards and certification to warrant functional safety in PLCs are IEC
61508 (Functional Safety of Electrical/Electronic/Programmable Electronic
Safety-Related Systems) or IEC 62061 (Functional safety of safety-related
electrical, electronic, and programmable electronic control systems).
4. Functional Safety Standards Related to Programmable Logic
Controllers
IEC 61508 is accepted as the master functional safety standard of
Electrical/Electronic/Programmable Electronic (E/E/PE) safety-related systems.
This standard addresses the factors that must be considered when employing
E/E/PE systems to perform safety functions. The key puprose of IEC 61508 (IEC
61508-1:2010 Functional Safety, Smart City, 2010) is identified as “to facilitate
the development of product and application sector international standards by the
technical committees responsible for the product or application sector.” This
statement defines the responsibilities of the technical committees for specific
product or application sectors to comprehensively consider all factors correlated

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with the product or application. The goal is to guarantee the resulting standards
meet the demands of users within the specific sector. If product or application
sector international standards do not exist, IEC 61508 allows the development of
E/E/PE safety-related systems. IEC 61508 is a fundamental document that guides
the enhancement of sector-specific standards, ensuring a consistent and robust
approach to functional safety in E/E/PE safety-related systems across various
industrial applications.
The IEC 62061 Standard provides requirements and recommendations for
designing, integrating, and validating safety-related control systems (SCS) for
machines (IEC 62061:2021 Safety of Machinery, 2021). It applies specifically to
control systems that execute safety functions on non-portable machines, whether
working individually or in coordinated groups. This standard is part of the IEC
61508 framework and is specific to the machinery sector. The IEC 62061
standard specifies requirements for design and verification of safety-related
control systems for use in high/continuous demand mode. Its focus is on
functional safety requirements to prevent hazardous situations that arise directly
from the machine's hazards or from a group of machines working coordinately.
IEC 62061 establishes safety requirements for control systems in the machinery
sector, within the broader context of the IEC 61508 framework. Its objective is
to enhance functional safety and reduce risks associated with machines or
coordinated machine activities, without impeding technological progress.
European Union’s Machinery Directive 2006/42/EC outlines the essential
health and safety needs of general application, augmented by a variety of
additional requirements for certain types of machinery. The Directive “applies to
machinery, interchangeable equipment, safety components, lifting accessories,
chains, ropes, removable mechanical transmission devices as defined in Article
2 of the Directive” (Directive 2006/42/EC - Machinery Directive | Safety and
Health at Work EU-OSHA, n.d.).
x In Annex I of the Directive, critical health and safety requirements
regarding the design and production of machinery are specified in full
descriptions of the risks inclusive more specific hazards. Safety and
reliability of control systems are also defined in this annex.
x In Annex II, declarations related to machinery is presented.
x The CE conformity marking is given in Annex III.
x In Annex IV, categories of machinery are given for the specific
machines.

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 Assist. Prof. Dilşad ENGİN

x Annex V describes the safety components that must be used for

functional safety of the machinery.
x Assembly instructions, technical documentation regulations, and
assessment of conformity are also included in the following annexes,
either related to safety or not.
The details of the Directive can be read in (EUR-Lex - 02006L0042-20190726
- EN - EUR-Lex, n.d.).
Process sector safety instrumented system standard IEC 61508 is used by
manufacturers and device suppliers, and IEC 61511 is used by SIS designers,
integrators, and users (IEC 61511-1:2016, 2016). PLCs are used for machine
control and process control, adhering to standards for both under the umbrella of
main safety standard IEC 61508. Detailed correlation of IEC 61508 and IEC
61511 is depicted in Figure 1.

Process Sector
Safety
InstrumentedSyst
em Standards

Process Sector
Process Sector Software and
Hardware Application
Program

Using Hardware Developing Developing

Developing Application Application
Developed and
Developing New Using Prior Use Embedded Program Using Program Using
Assessed
Hardware Devices Hardware Devices (System) Software Full Variabilty Limited Variabilty
According to IEC
Follow IEC 61508 Follow IEC 61511 61508 Follow IEC 61508- Languages or Fixed Program
3 Follow IEC 61508- Languages
Follow IEC 61511
3 Follow IEC 61511

Figure 32 Detailed correlation of IEC 61508 and IEC 61511 as described in IEC 61511-
1.
PLC manufacturers provide end-users with certified safety architectures based
on the required safety functions for machines and their surroundings. They also
give support and assistance to implement machine safety solutions from safe stop
of various motors to motor starters and light curtains that meet the safety integrity
levels (SILs), the latest regulations and compliance with new functional machine
safety standards. SIL reports and certificates typically focus on hardware safety
integrity but may neglect other critical aspects such as systematic safety integrity
and software safety integrity. Therefore, it is essential to address all perspectives
of safety integrity. It is imperative to recognize that a SIL is intricately tied to a
safety function. Therefore, assigning a SIL to a safety-related system without

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explicitly specifying the associated safety function is inappropriate. The accurate

definition of the safety function is essential for a meaningful and effective
assessment of safety integrity levels (Brissaud et al., 2015).
Protective guard devices are crucial components of safeguarding systems in
the hardware part of safety architecture. They control access under specific
conditions to minimize the risk of harm to humans. Various types of protective
devices are employed based on the nature of the potential hazards in an industrial
setting utilized to detect the approach of individuals to hazardous or restricted
areas. Light curtains that use optical sensors to create an invisible barrier,
triggering safety measures if the barrier is breached, are used to prevent access to
dangerous and limited zones. Two-hand control stations employed for certain
machinery or processes require simultaneous activation by both hands of the
operator to initiate a potentially hazardous movement. Enabling switches are
designed and used to enable specific machine functions or dangerous movements
only when manually activated. They serve as a control mechanism to initiate
potentially risky actions and are typically used in conjunction with other safety
measures. Generic protective measures such as emergency stop ensures the
critical safety feature in risky working environments. When activated, it provides
an immediate and forceful interruption of machine operation, allowing quick
intervention in emergency situations.
These protective measures contribute to establishing a safer working
environment, aligning with industrial safety standards and regulations. Their
integration into safeguarding systems helps relieve potential risks and ensures the
well-being of operators in industrial settings.
Many safety-critical PLC applications require redundant hardware to increase
reliability. Redundancy involves having duplicated components (such as
processors, power supplies, and communication interfaces) that work in parallel.
If one component fails, the redundant one can take over to maintain system
functionality.
Safety modules, safety controllers, and safety PLCs are integral components
of safety systems designed to protect individuals and resources in industrial sites
during monitoring and processing. Each serves distinct functions in improving
safety measures.
In safety-critical applications, the Input and Output (I/O) modules connected
to the PLC have a crucial role. Safe I/O modules are designed with safety features
such as short-circuit detection, diagnostics, and redundancy.

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Safety modules are specialized units designed to manage a specific safety

function within a larger safety system. They monitor inputs from various safety
devices, such as sensors or emergency stops, and control outputs to devices like
contactors and drives. A safety module may be dedicated to monitoring a light
curtain, ensuring that a hazardous area is immediately secured if the light curtain
is breached.
Safety controllers are configurable safety devices capable of overseeing
multiple safety functions simultaneously. They provide a flexible and adaptable
approach to managing diverse safety functions within a system. A safety
controller might simultaneously manage two-hand control stations, emergency
stops, and other safety measures on a production line.
Safety PLCs are programmable electronic systems designed to execute both
safety and non-safety related tasks for machinery and equipment. They are
capable of programming and control of a wide range of safety functions while
performing general control tasks. Safety PLCs typically contain advanced built-
in diagnostic features that continuously monitor the system's health. These
features include self-checking routines, hardware diagnostics, and real-time fault
detection. If a fault is detected, the PLC can initiate a safe state or provide an alert
for maintenance. A safety PLC could manage safety functions like light curtains
and emergency stops, along with non-safety tasks such as motor control and
production sequencing. The choice among these components depends on the
complexity and specific requirements of the safety applications within an
industrial environment.
As PLC technology has developed, it became possible to communicate
between multiple devices like remote I/O, motor drives, and servo controllers and
other PLCs, allowing for the transfer of more data compared to the hard-wired
field devices. This was the commencement of the Industrial Communication
Network. Communication systems, specifically Functional Safety Networks, will
replace traditional safety systems. This will result in more effective safety
measures through the transmission of safety-relevant messages, enabling the
implementation of distributed functional safety systems (Peserico et al., 2021).
Ensuring safety in signal transmission is a crucial concern in automation systems
that involve the use of PLCs. When acquiring data from sensors, transferring data
to IoT platforms, and communicating between peer PLCs and SCADA servers,
safety is of paramount importance, particularly when dealing with harmful and
hazardous situations. The safety-critical applications require communication
between various safety devices and systems. Safety communication protocols,
such as PROFIsafe, Safety over EtherCAT, and CC-Link Safety are designed to
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ensure the integrity and reliability of safety-related data exchange. Klose et al.
(2021) offer to use safe and flexible communication systems between sensors,
logic, and actuators using the safety protocols and a vendor-independent service-
oriented platform for Machine-To-Machine communication which the OPC
Foundation released as the OPC Unified Architecture (OPC UA).
Fundamental principles for transmitting safety-critical messages through a
distributed network using fieldbus technology is described in the IEC 61784-3
where these principles align with the functional safety requirements of IEC
61508, providing a standardized method for ensuring the integrity of safety-
related communications. These principles are suitable for process control,
manufacturing automation, and machinery including communication via PLCs,
enhancing the safety and reliability of industrial systems.
The IEC 61158 standard for industrial communication networks, along with
its associated standards IEC 61784-1 and IEC 61784-2, provides communication
protocols that facilitate distributed control in automation applications (IEC
61158-1:2023 Industrial Communication Networks - Fieldbus Specifications -
Part 1: Overview and Guidance for the IEC 61158 and IEC 61784 Series, 2023).
Fieldbus technology, as defined by these standards, has gained considerable
acceptance and proven reliability, and will develop continuously referring to real-
time and safety-related applications.
IEC 61784-3 interprets the fundamental principles for functional safety
communications by referencing the IEC 61508 standard. It identifies multiple
safety communication layers, involving related protocols defined in IEC 61784-
1, IEC 61784-2, and IEC 61158.
Figure 2 illustrates the correlations between IEC 61784-3 and relevant safety
and fieldbus standards in machinery field. This visualization helps investors
understand the interconnectedness of these standards and their roles in ensuring
the reliability and safety of communication protocols in automation applications.

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 Assist. Prof. Dilşad ENGİN

Figure 2 Relation of IEC 61784-3 with machinery standards as described in IEC 61784-
3 (IEC 61784-3:2021 Industrial Communication Networks - Part 3: Functional Safety
Fieldbuses, 2021)

Figure 3 demonstrates the relations between IEC 61784-3 and relevant safety
and fieldbus standards in the process field.

Figure 3 Relation of IEC 61784-3 with process standards as described in IEC 61784-3
(IEC 61784-3:2021 Industrial Communication Networks - Part 3: Functional Safety
Fieldbuses, 2021)

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5. Conclusion
Engineers and programmers follow safety programming practices when
developing control logic for safety-critical applications. This includes using
proven and validated software development methodologies, implementing safety
interlocks, and avoiding complex or error-prone programming constructs.
Functional safety standards often require thorough documentation of the safety
concept, design, implementation, and validation processes. This documentation
helps ensure traceability and provides a basis for assessing the safety integrity of
the system. Periodic safety checks and maintenance activities are critical to verify
that the safety functions of the PLC are operating as proposed. This includes
checking for hardware integrity, updating firmware, and validating the continued
effectiveness of safety measures. By incorporating these measures, PLC
manufacturers and users can warrant functional safety in PLCs and ensure that
these devices operate reliably in safety-critical applications. Additionally,
collaboration with safety experts and obedience to industry standards contribute
to achieving and sustaining functional safety.
6. References
Azarmipour, M., Elfaham, H., Gries, C., & Epple, U. (2019). PLC 4.0: A
Control System for Industry 4.0. IECON Proceedings (Industrial Electronics
Conference), 2019-October, 5513–5518.
[Link]
Brissaud, F., Turcinovic, D., & Didier, T. (2015). Functional Safety for Safety-
Related Systems: 10 Common Mistakes. [Link]
Da Anunciaçao, P. F., De Lemos Dinis, V. M., Penalver, A. J. B., & Esteves,
F. J. M. (2022). Functional Safety as a critical success factor to industry 4.0.
Procedia Computer Science, 204, 45–53.
[Link]
Directive 2006/42/EC - machinery directive | Safety and health at work EU-
OSHA. (n.d.). Retrieved December 20, 2023, from
[Link]
european-parliament-and-of-the-council
EUR-Lex - 02006L0042-20190726 - EN - EUR-Lex. (n.d.). Retrieved
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Hajda, J., Jakuszewski, R., & Ogonowski, S. (2021). Security Challenges in
Industry 4.0 PLC Systems. Applied Sciences 2021, Vol. 11, Page 9785, 11(21),
9785. [Link]

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IEC 61131:2022 SER. (2023, November 23). International Electrotechnical

Commission Webstore. [Link]
IEC 61158-1:2023 Industrial communication networks - Fieldbus
specifications - Part 1: Overview and guidance for the IEC 61158 and IEC 61784
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Kotsch, C., Knab, J., Gut, B., Manske, H., & Urbas, L. (2020). Distributed
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& Urbas, L. (2021). Building Blocks for Flexible Functional Safety in Discrete
Manufacturing and Process Industries. IEEE International Conference on
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Peserico, G., Morato, A., Tramarin, F., & Vitturi, S. (2021). Functional Safety
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