Hands On: Introduction to Safety Workshop · Clamping plates > Crushing Chips > Cutting, penetrating ... Understanding Safety Levels - PL a Standard Switch and Contactor PL a allows

Hands On: Introduction to Safety Workshop Presented by…Robert Jones

Manufacturing in America │ March 14-15, 2018

Unrestricted © Siemens 2018 All rights reserved. Community. Collaboration. Innovation.

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Machine Safety

Safety Process Chain

Cutting disc > Cutting off

Transport rollers > Crushing and shearing

Clamping plates > Crushing

Chips > Cutting, penetrating

Risk assessment Risk reduction Proof

The necessary steps towards a safe machine can be illustrated with a process chain.


Machine Safety

Are Risk Assessments Required?


DIRECTIVE 2006/42/EC

(Machinery Directive)

European Union : USA:

NFPA 79 ANSI B11.19 ANSI / RIA 15.06 ANSI ASSE Z244.1

YES! All new & revised machine safety standards state that a “Risk assessment” MUST be

performed


Machine Safety

Methods of Risk Mitigation

Safety Implementations

• Physical safety measures

Barriers (e.g. guards, enclosures), protective clothing and

equipment, floor markings

• Safety awareness

General safety education courses, proper equipment training,

regular internal safety evaluation

• Safety controls

Input devices (e.g. sensors, pilot devices), safety evaluation

devices, Output devices (e.g. contactors, motor starter protection)


Machine Safety Risk Assessment Process

The following standards should be applied for the techniques to evaluate and assess these risks:

For USA: ANSI B11.0 - 2010, Safety of Machinery; General Requirements And Risk Assessment.

For Europe: EN ISO 12100 "Safety of machinery – basic terminology, general principles for design – risk assessment & risk reduction“


Machine Safety

Quantifying Risk

Risk assessment Risk reduction Proof Risk assessment


Machine Safety

Determination of required SIL

Risk assessment Risk reduction Proof Risk assessment


Machine Safety

Determination of required PL

Risk assessment Risk assessment Risk assessment Risk reduction Proof Risk assessment


Machine Safety

Typical Safety Circuit – example SIL 3 / PL e wiring

24V or 115VAC Power Supply

0V

Sensors

Initiate machine shut

down

Positive Opening

Guarantees that all

NC contacts are in

the open position

when actuated

Redundancy

ensures safety

functionality even if a

failure disables one

channel

Evaluation

Fault detection and

evaluation; opens the

circuit in case of a

failure.

Positive Driven (Mirror)

Guarantees that NC contacts are

not to be closed at the same time

as the main contact

Feedback Loop

Monitors the correct

operation of the

contactor coils

Reset

Reactivates the

safety circuit

The Complete Safety Solution

Safety Controller

OR


Machine Safety

Understanding Safety Levels - PL a

Standard Switch and Contactor PL a allows

• NO contacts for

• Enabling

• Two-hand control

• Restart

L1 L2 L3



Machine Safety

Understanding Safety Levels - PL b

24 VDC

0 VDC

Op

en

Clo

se

d

PL b requires

• Sensors with positive

opening contacts

L1 L2 L3



Machine Safety

Understanding Safety Levels - PL c / SIL 1

And


opening contacts

• Safety evaluation unit rated

to SIL 1

• Feedback loop from

contactor’s NC contacts

24 VDC

0 VDC

Op

en

Clo

se

d

PL c / SIL 1 requires

ON

L1 L2 L3

Q1



Machine Safety

Understanding Safety Levels - PL d / SIL 2

And


opening contacts


to SIL 2



• Redundancy in sensor

contacts

• Redundancy in contactors

24 VDC

0 VDC

Op

en

Clo

se

d

PL d / SIL 2 requires

ON

L1 L2 L3

Q1

Q2



Machine Safety

Understanding Safety Levels - PL e / SIL 3

And

24 VDC

0 VDC

Op

en

Clo

se

d

ON

L1 L2 L3

Q1

Q2


opening contacts


to SIL 3



• Redundancy in sensor

contacts

• Redundancy in contactors

• Separate channels of

evaluation for sensors

PL e / SIL 3 requires



Machine Safety

Risk Reduction

•Solutions consist of three main components

Detection Evaluation Reaction


Very Important as this is how the safety function is defined when doing the calculations for SIL/PL levels


Input Devices

May Include Several or Just One of the

Following:

(Depending Upon Safety Category Desired)

Mechanical Input Devices

• Emergency Stop (with or without enable

or resets)

• Position Switch

• Interlock Switch

Detection


Input Devices


Following:

(Depending Upon Safety Category Desired)

Electronic Input Devices

• Solenoid Interlock Gate Switches

• Magnet or RFID Position Switches

• Light Grids / Area Laser Scanners

• Encoder Position Switches

• Safety Mats

Detection


Input Devices with Safety Protocol using

Networks

Mixed Safety – Non-Safety Devices same

Network

• AS-I Safe

• Profi Safe

Detection


Flowchart - Guides you to the right Siemens Safety Solution

To fit your applications safety functionality, as per your comfort level

Detection


Safety Relay & Programmable

Controllers

May Include One, Several, or a Combination

of the Following:

(Depending Upon Safety Category Desired

and Complexity)

• Safety Relays

• Configurable Safety Relays

• MSS (Modular Safety System)

Evaluation


3SK, Universal Functionality

Simple

Slim portfolio

+

Flexible

Extendable through modular product

concept

+

Combinable

With motor starter SIRIUS 3RM1

Failsafe

+

Multifunctional

Parameterization via DIP switch or

software

+

Economic

Simple and reduced wiring with usage of

innovative device connector

+

Evaluation


Modular expandability of SIRIUS Safety Relays 3SK1

Reduction of wiring outlay and space saving despite higher functionality

Evaluation


3SK1 compared with 3SK2

3SK1 customer’s requirement 3SK2

most simple logic

more complex logic

additional functions

(e.g. Muting/Interlock)

only wiring allowed

time off delay

complex time functions

powerful outputs

enhanced diagnostics

simplification of commissioning

less space consumption

Evaluation


Parameterization, Configuration, Visualization

Safety ES Software

• Allows for comprehensive documentation

thanks to graphical Drag&Drop code

interface

• Easy-to-use configuration tools turn

complex wiring parameterization into

straightforward software solutions

• Makes implementing advanced functions

easy:

• Muting functionality

• Protective door monitoring

• Independent output functions

Evaluation


Modular Safety System (3RK3)

Designed to minimize the number of

modules needed when multiple safety

functions must be evaluated.

• 3RK3111/3RK3131 (Basic/Advanced

central unit)

• 3RK3121/3RK3122 (Basic/Advanced

central unit with ASI safe integration)

• Expansion modules, DP interface

module, and diagnostic display available

Evaluation


SIMATIC Failsafe CPUs

Failsafe versions of the SIMATIC

automation system integrate additional

safety-related functions

• S7-1200F: High level functionality and

flexibility.

• ET200SP F: Distributed controller for

compact systems.

• S7-1500F: Greatest performance,

flexibility and networking capability.

Evaluation


Output Devices


Following:

(Depending Upon Safety Category Required

& Operation Desired)

• Safety Contactors (Positively Driven –

Mirror Contacts)

• Safety Relays (Positively Driven – Mirror

Contacts)

• Safety Motor Starters (3RM1 / ET200S /

ET200SP)

• Safety VFDs (G120 / S120)

Reaction


Siemens Safety Integrated

Safety Design Compliance - Safety Evaluation Tool

The Safety Evaluation tool

• A free Internet-based tool for calculating safety functions

• ISO 13849-1 (successor standard of EN 954-1)

• IEC 62061

• For documenting the results by a report

• Offers easy, identical handling for both standards

• Optimum support when using the Siemens products

Safety Evaluation Tool – Online Access

SET – Getting Started Document

SET Tutorial (YouTube)


http://www.industry.siemens.com/topics/global/en/safety-integrated/machine-safety/safety-evaluation-tool/Pages/default.aspx




http://www.industry.siemens.com/topics/global/en/safety-integrated/machine-safety/safety-evaluation-tool/Documents/SET-Getting-Started_EN.pdf




https://www.youtube.com/watch?v=oZqsmYo9Vq4&hd=1


Siemens Safety Integrated

Machine Safety Services

Risk Assessments

Partners

• GP Strategies

• White Horse

Safety

Safety Validation

Partner

• TÜV Rheinland

of North America

• White Horse

Safety



Wheat mill with variable feeding

Requirements

Alternating monitoring of cone or

vessel

manipulation-proof switches

door interlock of service door (crushing

mill)

door interlock of service door (vessel)

nearly no space in cabinet



Solution

Solution with HW-parameterized

Safety relays

Solution with SW-parameterized

Safety relays 3SK2



Solution

Required 3SK1 Wiring Required 3SK2 Configuration


Material Feeding System: 3SK2 Example

Inspection Station

Tool Change/Access


Safety Controls Components: 3SK2 Example

Emergency Stop

- Global

Reset Button

RFID Gate switch

- Safety Motor Starter

Light Curtain

- Contactors

Programmable Safety Relay

Safety Motor Starter

- Conveyor

Contactor

- Robot

Detection Devices Evaluation Devices

Reaction Devices


Evaluating SIL Level: 3SK2 Example

Hazard 1: Conveyor

• Severity: 3, Loss of fingers

• Frequency: 5, ≤ 1 Hr

• Occurrence: 2, Rarely

• Preventability: 1, Probable

• Total: 8

• SIL Level: 1

Hazard 2: Robotic Arm

• Severity: 4, Loss of life

• Frequency: 3, > 2 Weeks to 1 Year

• Occurrence: 3, Possible

• Preventability: 5, Impossible

• Total: 11

• SIL Level: 3


Safety ES Software: 3SK2 Example

Cross-circuit

detection with

monitored start E-Stop and

pushbutton inputs

Outputs to 3RM1

through

backplane and to

contactors

3SE6 Inputs Cross-circuit

detection,

automatic start

3SE6 Ouput to

3RM1

Wired output to

3RM1

E-Stop global output


Safety ES Software: 3SK2 Example

Inputs from E-stop

output block (M1,

M2) and Light

curtain (M3)

Mirror E-stop condition

output to LED (QM1) and E-

stop and light curtain must

not be tripped for contactor

LED (QM2) to be on

Red E-stop LED

(QM1) Green

contactor LED

(QM2)

Light curtain inputs and push

button inputs, Input from E-

stop output (Q5-C)

Light curtain and E-stop

must not be tripped,

controls contactors Contactor Feedback

Output to

Contactors

Contactors (Q1, Q3)

and Auxiliary to

LED (M3)


Hands On Demo Unit Layout: 3SK1

3SK1 Basic Unit

Contactor Q1 E-Stop, Monitored Contacts

Red Status LED

Contactor Q2

5SJ4 2A Circuit Breaker

Reset Button


Task #1: 3SK1 SIL 1 Wiring


Goal:

Demonstrate the ease of setup and flexibility of the 3SK1 series with a SIL 1

configuration.

Main take away items:

• Understand the application of SIL 1 safety measures in system design.

• Integrate the 3SK1 into a safety system to satisfy SIL 1 standards.


Task #1: 3SK1 SIL 1 wiring


Technical Diagram




Recap

• Sensor with positive opening contacts

• Lower rate of failed detection from shorts and welds

• Safety evaluation unit rated to SIL 1

• More reliability and higher level safety functions

• Feedback loop from contactor’s NC contacts

• Provides feedback if contactor contacts weld

• Picture of demo in SIL 1

configuration



Goal:

Demonstrate the ease of setup and flexibility of the 3SK1 series with a SIL 3

configuration.

Main take away items:

• Understand the application of SIL 3 safety measures in system design.

• Integrate the 3SK1 into an existing system to satisfy SIL 3 standards.




Technical diagram




Recap

• Safety evaluation unit rated to SIL 3

• More reliability and higher level safety functions

• Separate channels for each set of sensor contacts

• Failure of a single channel does not disable safety

functionality

• Picture of demo in SIL 3

configuration


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Seminar Slides

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Questions?

Robert Jones

6750 Arnold Miller Pkwy

Solon, OH

Phone: (330) 980-1133

E-mail: [email protected]