Metal Coating Line Burner Management Safety Controls 


The project focused on two new metal coating lines and their line burner management safety controls. The two plants were installed in overseas locations and required a review to ensure the plant conformed and was in compliance with Australian standards.

Initially, our engineering team attended and reviewed a control hazard and operability study (CHAZOP). When reviewing the project relative to compliance with Australian standards and regulations, it became apparent there were deficiencies in the design and its operational functionality. Consequently, we advised on these issues and devised changes to improve the systems with better line burner management safety controls. Issues included not only a lack of compliance but also insufficient protection of controls during device failure or incidents.

Our team moved distributed control system code to the gas safety system and modified it to maintain working functionality. Overall, we made the system safe for startup by adding additional interlocks and, as such, ensuring system compliance with the required Australian standards.


  • Investigate existing systems for compliance and then design control and instrumentation systems to meet site conditions and project requirements.
  • Participate in both hazard and operability (HAZOP) and control hazard and operability (CHAZOP) studies to ensure a thorough evaluation of existing system infrastructure and requirements.
  • Supply and also install fibre from the programmable logic controller (PLC) to the plant network and ensure a sturdy connection. 
  • Design a burner management system to meet Australian Standards and any other regulatory requirements to ensure compliance.
  • Carry out and install all instrumentation tubing to valves.
  • Move the hydrogen and nitrogen gas mixing functions to a safety integrity level (SIL) rated control system.

Control systems

  • Yokogawa Centum Control System CS3000 (Existing).
  • Pilz Programmable Control System PS3000.


  • Move distributed control system (DCS) code to the Gas Safety System.
  • Modify DCS code to maintain working functionality.
  • Importantly, ensure system compliance with Australian Standards and all relevant regulations.