Retrofit of a switchgear system with complex safety functions
As part of the modernization of a Saint-Gobain Rigips production facility, functional safety was to be brought into compliance with current technical and regulatory requirements. The challenge was to integrate automation and safety concepts—which had evolved over many years and involved different generations of control systems—into a unified safety architecture.
As part of various retrofits, new safety doors with door interlocks, light curtains, and other safety devices were installed. At the same time, existing automation components were to continue to be used wherever it made technical and economic sense to do so. The goal was to modernize the safety-critical areas without significantly disrupting proven production processes or limiting system availability.
gefeba developed a comprehensive safety concept based on fail-safe Siemens control technology and gradually replaced existing, predominantly hardware-based safety solutions with a modern F-PLC architecture.
The implementation was based on existing risk assessments, safety matrices, and safety layouts, which were used to analyze, evaluate, and reimplement all safety functions. As part of the project, new safety control systems were installed, and existing control systems were expanded and modernized. Existing automation components were selectively reused and integrated into the new safety concept.
The new safety architecture includes, among other things, emergency stop systems, door monitoring with door interlocks, light curtains, safe position monitoring, and enable buttons. Communication takes place via Profinet and PROFIsafe, enabling flexible and transparent implementation of the safety functions. In addition, gefeba handled the adaptation of the hardware documentation, the expansion of the network infrastructure, the creation and migration of the safety programs, and the complete testing and verification documentation. Even during the ongoing modernization, numerous change requests were implemented on short notice and integrated into the safety concept.
Thanks to the modernization, the plant now has a uniform, transparent, and future-proof safety structure. Safety functions are implemented centrally using modern, fail-safe control technology, making them easier to expand, adapt, and maintain.
At the same time, the new system architecture improves the long-term availability of replacement parts as well as the system’s serviceability. Standardized safety functions, up-to-date hardware, and a modern engineering environment lay the foundation for safe and cost-effective plant operation for many years to come. In addition, the clear structure of the safety architecture facilitates maintenance, troubleshooting, and future expansions of the production facility.
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We develop customized solutions—from analysis through the engineering phase to commissioning and support. Our focus is on maximum functionality, on-time delivery, and durability.
Our project work is supported by collaborations with leading technology partners such as Siemens, Rittal, B&R, and Proxmox, which provide the technological foundation for our project results and help expand them.
