Hydraulic systems are fundamental to the performance of many industrial and marine operations where precision motion and control are essential for manipulating mechanical components and systems. 

Now, this same precise regulation and control can be harnessed to deliver advanced safety measures elevating operational safety to new industry standards. 

The accredited FPS SAFE STOP Safety System – designed, developed and manufactured by Gary Allen and the team at FPS in Nelson, New Zealand – offers a fully integrated suite of proactive and reactive safety solutions engineered to protect people like never before.

Initially developed for the marine industry by FPS’ industry leading hydraulic engineers, the SAFE STOP system leverages FPS’s proprietary, accredited marine-grade technology to reduce user error and safeguard staff. 

SAFE STOP’s modules can be fully customised to suit your safety requirements and seamlessly integrated into both new and existing hydraulic systems. The system is also available in standard materials for below deck installations and other industrial applications where corrosion is not an issue, such as sawmills, food processing facilities and beyond. All systems are designed to be serviceable and easy to maintain.

SAFE STOP Manifold on MacLab’s aquaculture vessel, the Vanguard, including a Reset Module and three Sensing Modules. 

FPS’s hydraulic engineers design solutions that align with both your safety requirements and the technical demands of your machinery. There are a variety of modules available:

SAFE STOP Hydraulic Position-Sensing Valve 

SAFE STOP Hydraulic Position-Sensing Valves offer a proactive layer of protection, designed to prevent harm before it happens. Engineered to automatically shut down equipment when critical safety thresholds are breached, such as access panels being opened or safety guards removed, these intelligent valves act as a frontline defence against mechanical injury. 

For instance, if an operator opens a hatch or access point, the valve triggers an immediate hydraulic response, shutting down machinery as specified. The system can be configured to stop a single machine, isolate a defined zone of equipment, or halt operations across an entire vessel, factory floor, or industrial site, offering control at a level that suits your operational context.

Built with dual modular redundancy, each unit ensures fail safe performance. In the unlikely event one valve fails, the secondary unit automatically engages, providing continuous protection without compromise. 

SAFE STOP Emergency Stop Modules 

SAFE STOP Emergency Stop Modules offer enhanced protection by integrating directly into your hydraulic system, delivering a rugged, manual emergency stop solution designed for real-world operating environments. 

These hydraulic emergency stop valves can function independently or be used in conjunction with traditional electric emergency stop switches, providing a dual layered safety approach that ensures reliability where it matters most. 

With SAFE STOP, you decide the scope of the shutdown. Strategically positioned within your operation, each module can be configured to deactivate a single piece of equipment, a specific operational zone, or your entire system. To further enhance protection, the system includes intelligent safeguards. 

Consider this scenario: if an emergency stop triggers a full system shutdown, the system will not reset if a piece of equipment – such as a winch – was left in an active state. The system will remain locked until all controls are returned to a neutral position. This prevents machinery from unexpectedly re-engaging, ensuring that operators remain in full control and staff are not exposed to unexpected movement. 

SAFE STOP Reset Module 

The SAFE STOP Reset Module ensures that machinery cannot be restarted until it is fully safe to do so, serving as a critical safeguard within the overall SAFE STOP safety architecture. 

When paired with the Hydraulic Position-Sensing Valve Module or the Emergency Stop Module, the Reset Module governs the reactivation of the machinery, system or designated operational zone under its control. 

In the event of a shutdown – whether planned or triggered by a safety incident – the Reset Module prevents restart until all machinery controls have returned to a safe, neutral state. This intelligent safety interlock ensures that no equipment restarts unexpectedly, preventing potential harm to operators and protecting the integrity of your operations. 

SAFE STOP Reducer Module

The SAFE STOP Reducer Module plays a vital role in maintaining controlled hydraulic pressure within your safety system, ensuring reliable and consistent operation of all SAFE STOP components. 

In some configurations, FPS engineers may integrate existing pressure sources from other parts of the hydraulic system, such as pressure from active components already in operation. However, the dedicated Reducer Module is recommended for optimal control and reliability, particularly in complex or high-risk environments. 

By managing pressure with precision, the Reducer Module ensures that your safety system performs exactly as intended every time.

SAFE STOP Sensing Modules

The SAFE STOP Sensing Modules work in conjunction with the Reset Module to determine whether conditions are safe for the system to restart, providing real time feedback from various types of control valves throughout your operation. 

Designed to interface with a wide range of valve types including manual, electric, and hydraulic remote-controlled valves, each sensing module is tailored to accurately detect the position and status of the equipment it monitors. By verifying that all components are in a safe, isolated state before a system restart, these modules prevent machinery from unintentionally reactivating. 

For example, if a machine was left running at the time of an emergency stop, engine failure, or the opening of a guard or access panel, the sensing modules ensure that it cannot resume operation until all controls are returned to a safe condition. Sensing Modules provide a vital layer of assurance, ensuring your entire operating environment is safe before restart is permitted. 

SAFE STOP Isolating Modules

The SAFE STOP Isolating Modules / Plunger Valves are integrated into each critical zone of your system and work in direct communication with the Reset Module and Sensing Modules to enforce strict isolation protocols. 

By design, these modules physically isolate individual machines, operational zones or the entire hydraulic system. Isolating Modules ensure that a restart cannot be forced or bypassed. Every zone requiring controlled safety will be equipped with one of these modules. Their intelligent design includes dual modular redundancy. If one valve fails, a secondary valve takes over, guaranteeing a safe system shutdown under any circumstance.

Available exclusively from FPS. Contact Brent Brown to discuss a custom SAFE STOP solution tailored to your safety needs. Email brent@fluidpower.co.nz or call (+64) 3 548 4850 EXT 105. 

Learn more at www.fluidpower.co.nz/services/safe-stop-system-design