Functional Safety
Client: Wilmar
Functional Safety Rail Systems engineering was critical to the successful design and integration of Wilmar’s remotely operated rail points control system. Cell Engineering was approached by Wilmar to design and integrate a rail point system to be remotely operated using functional safety-rated systems. The scope included references to AS 61508, 61511, and AS/NZS 4024 series.
The process included:
- Document requirements in a functional safety requirements specification.
- Complete detailed designs, including safety PLC programming, HMI interfacing, networking, and integration for the agreed systems needed and identified from the RA.
- Model the intended failure rates in the Sistema software.
- Perform Bench testing of the three interfaced safety PLCs, with final commissioning of the system scheduled for 2025.
Rail Systems Engineering Scope
Cell Engineering was engaged to design and integrate a remotely operated rail points system using functional safety-rated infrastructure aligned with recognised Australian and international safety standards. The project involved preparation of a Functional Safety Requirements Specification (FSRS), detailed engineering design, safety PLC programming, HMI interfacing, networking integration, and support for operational safety requirements identified through the project risk assessment process. Our engineering team also modelled intended failure rates using Sistema software to assess system reliability and support compliance with AS61508, AS61511, and AS/NZS 4024 standards.
Functional Safety and Industrial Automation
Functional Safety Rail Systems play a critical role in supporting safe and reliable industrial operations where remotely operated equipment and automated infrastructure require controlled operational risk management.
By combining practical electrical engineering expertise with industrial automation and operational technology capabilities, Cell Engineering helped support the safe integration of rail infrastructure systems aligned with operational and compliance requirements.
Safety PLC and HMI Integration
The project required integration between multiple safety PLC systems, HMI interfaces, industrial networking infrastructure, and field devices to support reliable remote rail points operation.
Bench testing activities were completed for the three interfaced safety PLC systems prior to final commissioning activities scheduled for 2025. This process helped verify operational performance, communication reliability, and alignment with project safety objectives.
Functional Safety Rail Systems Across Australia
Cell Engineering delivers Functional Safety Rail Systems, operational technology, industrial automation, and electrical engineering solutions across mining, industrial, infrastructure, and utilities sectors throughout Australia.
With offices in Brisbane, Mackay, Darwin, Gladstone, and Newcastle, Cell Engineering provides local engineering support backed by national capability and industry expertise. Our Electrical Engineering Consultancy Australia-wide capabilities allow us to support clients locally while delivering nationally consistent engineering standards.
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Explore additional services related to electrical safety and hazardous area design offered by Cell Engineering.
Rail Infrastructure Safety and Operational Reliability
Functional Safety Rail Systems require reliable communication, controlled operational logic, and robust safety integration to ensure safe and efficient industrial operation.
The Wilmar rail points project required close coordination between functional safety requirements, operational control systems, industrial networking, and electrical engineering design principles. Cell Engineering supported the project through detailed engineering design, system integration, testing activities, and preparation for final commissioning.
Functional safety systems are critical for reducing operational risks associated with remotely operated rail infrastructure, particularly where multiple automated systems and operational interfaces are involved. By applying structured engineering methodologies and recognised safety standards, Cell Engineering helped support safe operational outcomes, improve system reliability, and ensure compliance-focused project delivery.
Our multidisciplinary engineering team continues to deliver operational technology, industrial automation, safety PLC integration, and electrical engineering solutions across mining, industrial, infrastructure, and utilities sectors throughout Australia.
Cell Engineering Pty Ltd continues to support Australian industry with practical engineering solutions focused on safety, reliability, operational performance, and long-term infrastructure outcomes.
Time Frame:
2025
Approx. Value:
$152,000
