Realization and Functional Safety Assessment of the National Modular Microprocessor-Based Interlocking System KZ-MPC-MA

This study investigates the realization and verification of safety-related functions of the KZ-MPC-MA national modular microprocessor-based railway interlocking system for Kazakhstan. The work focuses on the realization stage of the IEC 61508 safety lifecycle and establishes traceability between station-specific safety requirements, interlocking algorithms, software implementation, hardware–software integration, and functional-safety assessment. The implemented interlocking logic incorporates 29 traffic safety conditions defined for the considered station configuration. A fail-safe control architecture based on central and distributed controller modules was implemented using certified safety-related industrial controllers and the SILworX development environment. A laboratory prototype was developed to verify route-setting functions, switch and signal control, and fail-safe system response under specified operational and failure conditions. Quantitative functional-safety assessment was performed using the probability of failure on demand (PFDavg) as a supplementary measure and the probability of dangerous failure per hour (PFH) as the governing criterion for continuous/high-demand operation within the defined assessment boundary and assumptions. The obtained PFH demonstrates that the investigated safety-related controller subsystem satisfies the specified SIL4 quantitative criterion. The study demonstrates the feasibility of realizing safety-related interlocking functions on the selected hardware–software platform and provides a basis for further system-level verification and validation.