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REPORT nº 2704A35
CONFORMITY ASSESSMENT REPORT
SAFETY SYSTEM, ACCORDING TO NR 12
RUBBER INJECTOR MOD. REP RT9-250Y20-A
2
DME Engineering - Consulting - Projects - Management
Phone: +55 11 4653-3124 / Cell Phone: +55 11 96734-2188
MANUFACTURER
Name:
Address:
CNPJ:
COMPANY REPRESENTATIVES
In response to a request from this reputed company, through its representatives Mr.
- Administration and Sales & Mr. - Coordination and Post Sales, we present the
appraisal report of the equipment in compliance with the provisions required by NR-
12 (Regulatory Norm Number 12 - Machinery and Equipment).
TECHNICAL REPRESENTATIVE FOR THE ELABORATION OF THE
REPORT
Responsible for preparing the report: Carlos Alberto de Oliveira Technologist in
Automation & Glauton Machado Barbosa, Mechanical Project Engineer.
TECHNICAL INFORMATION ABOUT THE ASSESSED EQUIPMENT
Device: Rubber Injector
Model: RT9-250Y20-A
3
DME Engineering - Consulting - Projects - Management
Phone: +55 11 4653-3124 / Cell Phone: +55 11 96734-2188
Summary
1 Normative References ................................................................................................. 4
2 Objectives and Methodology ...................................................................................... 4
3 Basic Summary ............................................................................................................ 4
3.1 Definitions ............................................................................................................... 5
3.1.1 Mechanical Protection Fixed ................................................................... 5
3.1.2 Mechanical Protection Mobile ................................................................ 5
3.1.3 Security sensors .......................................................................................... 6
3.1.4 Emergency Stop Device ............................................................................ 6
3.1.4.1 Suitable Signage ................................................................................. 6
3.1.4.2 Acting Right ........................................................................................ 6
3.1.5 Electrical Command .................................................................................. 7
4 Evaluation NR12 ........................................................................................................... 7
4.1 Drive System ........................................................................................................... 7
4.2 Machine Safety Monitoring .................................................................................... 9
4.3 Remote Actuator Monitoring ................................................................................ 11
4.4 Emergency Stop System ....................................................................................... 13
4.5 Manual Reset ........................................................................................................ 15
4.6 Electrical Panel / General Switch with Lockout for De-energization ................... 18
4.7 Operation Signaling .............................................................................................. 20
4.8 Electrical and Hydraulic Manuals / Diagrams ...................................................... 21
4.9 Pressurized Components ....................................................................................... 22
5 Responsibilities .......................................................................................................... 24
5.1 Elaboration ............................................................................................................ 24
5.2 Technical and Legal Responsible ......................................................................... 24
5.3 ART ....................................................................................................................... 25
4
DME Engineering - Consulting - Projects - Management
Phone: +55 11 4653-3124 / Cell Phone: +55 11 96734-2188
1 Normative References
ABNT NBR NM 272 - Machine safety - Protections - General requirements for the
design and construction of fixed and mobile guardsNBR 5410 - Electrical installations
of low voltage
NBR 5410 - Electrical installations of low voltage
NR10 - Facilities and Services in Electricity
NR12 - Safety in Machinery and Equipment
2 Objectives and Methodology
The purpose of this Technical Report is to evaluate compliance in compliance with
regulatory requirements, to verify the condition of safe operation, to inform about the
risks that the machine offers which are the prevention or protection measures that exist
to control the risks, which The chances of hazards being eliminated, and which parts of
the machine and equipment are subject to injury and damage. The methodology used for
this report was an analysis of the electrical diagram, hydraulic diagram, technical audit
visit was not performed on this machine model to verify the equipment in question to
prove the information, then a visit was made in a previous version to that one.
3 Basic Summary
The Technical Report on Conformity Assessment consists basically of the following
information:
• Short technical description of the machine;
• Indication of any non-conformities, marked in red, accompanied by solutions for
their sanitation, according to NR-12;
• Indication of any conformity, marked in green.
5
DME Engineering - Consulting - Projects - Management
Phone: +55 11 4653-3124 / Cell Phone: +55 11 96734-2188
Injection press mod. RT9-250Y20-A - Clasp type, vertical; Hydraulic drive; capacity
2450KN.
3.1 Definitions
SAFETY SYSTEMS (SAFETY PROTECTIONS OR SAFETY DEVICES OR
THEIR COMBINATION TO PREVENT ACCESS TO RISK OR DANGEROUS
MOVEMENTS) In accordance with items 12.38 to 12.55.1 - NR-12, General
Provisions.
3.1.1 Fixed Mechanical Protection (Fixed physical barrier, or fixed protection,
according to NR-12, item 12.38 - General Provisions).
It is the one fixed by screws which can only be removed with tools, and can not
be bolts of the butterfly type, rings or any other modality that allows their removal by
hand, according to ABNT NBR NM 272. The condition of fixed mechanical protection
is Only required in the operating cycle, but the other steps of use (maintenance
adjustment and etc.) require the complete stop of the movements to remove the
protection. For the application of the exception provided for by the NR-12, for the
maintenance stages, a documented justification, which is subject to evaluation and
reception or not, by the public worker's health and safety agent is required.
3.1.2 Mechanical Protection Mobile (Mobile physical barrier, or Mobile protection,
according to NR-12, item 12.38 - General Provisions).
It is one that allows movement during the normal operation cycle, but requires a
safety interlocking capability, according to ABNT NBR NM 273, or locking device,
according to the machine mode and mode of operation and according to the nature of
the risks (*).
(*) There are specific situations that require the simultaneous use of interlocking and
blocking.
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DME Engineering - Consulting - Projects - Management
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3.1.3 Security Sensors (According to NR-12 item 12.42, letter "c" - General
Provisions) Device that allows access and entry into the risk area, but ensures the
machine is stopped, preventing the reach of the risk area, under risk conditions. The
invasion of the hazardous area is detected and sends a signal to stop or prevent the onset
of dangerous movements or functions. (examples are: light curtains and other
optoelectronic presence detectors (AOPD), multi-beam laser, optical barriers, area
monitors, scanner devices, security mats and position sensors)
3.1.4 Emergency Stop Device (Conditions required for emergency button with
principles equally applicable to other emergency stop modes):
3.1.4.1 Appropriate Signaling
Emergency button (or other mode) is properly signaled when simultaneously
meeting the following conditions:
• Identification base of the word EMERGENCY, as a facilitating
recommendation for the identification, in yellow / black letter and in
Portuguese.
• Emergency button in red color, mushroom latch type, which can be triggered
without difficulty with the palm of the hand.
3.1.4.2 Appropriate performance
Emergency button displays proper performance when you simultaneously meet
the following conditions:
• It is a locking / mushroom type (tightening sinks, requiring the unlocking to
start operation);
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• Requires manual reset ( the emergency button unlocking can not enable the
machine to be triggered without the reset button being pressed;
• Ensures machine standstill, with prompt stop of all movements of the
monitored machine.
3.1.5 Electrical Command (Or Safety Interface, according to NR-12, treated by
Process Unit by Manufacturers) to monitor safety devices (so-called by the NR-12,
which are electronic actuators / optoelectronic / electromechanical Configure action at a
distance): According to item 12.42 letter "a" - NR-12 - General Provisions.
All remote actuators (pushbuttons, emergency buttons, restraints, light curtains,
interlocks, safety valves, others) must be monitored by a suitable process unit (Safety
Interface), which may be one of the Three modes: safety relay, safety PLC or Safety
CCS (configurable controller).
4 Rating NR 12
4.1 Drive System
• Injector hydraulic motor / pump drive is powered by an on / off (green-on / red-
off) system located on the front panel of the machine's electrical panel.
• Electrical circuit prevents start / restart of the cycle (on / off), before any stop
(emergency / interlock).
• Power button, is only reactivated with the mechanical activation of the emergency
(unlock) button.
• Off button, prevents any reactivation of the hydraulic pump motor.
• The start, stop and start components operate at extra low voltage.
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.
System Identification On / Off Hydraulic Pump
Electrical Diagram - Hydraulic Pump On / Off System
9
DME Engineering - Consulting - Projects - Management
Phone: +55 11 4653-3124 / Cell Phone: +55 11 96734-2188
Legal base
Condition required by Items 12.24 to 12.37 (Start, start and stop devices)
Injection press mod. RT9-250Y20 W-101/1 ODM6236 S1- Type of closure, vertical;
Hydraulic drive; Closing force 91.6KN.
4.2 Machine Safety Monitoring
The RT9-150Y10 Injector has safety monitoring on the front of the machine
through category 4 light curtain (PX31), with interlocking lock in category 4 SICK
safety relay, limit switches (LS3) and (LS4) All with interlocked interlocks in Category
4 emergency stop relay of the Schneider Electric brand.
CAT.4 - B50 Light Curtain
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Electrical Diagram - Light Curtain and Cat.4 Safety Relay
Electrical Diagram - Safety Stop Switches and Emergency Stop Relay Cat.4
11
DME Engineering - Consulting - Projects - Management
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Legal base
Condition Required by items 12.38 to 12.55 of the general provisions and Annex VI of
NR-12.
4.3 Remote Actuator Monitoring
The equipment has a safety monitoring system consisting of a category 4 SICK
safety relay with Category 4 light curtain interlocking, Schneider Electric category 4
emergency stop relay with interlocking limit switches (Electromechanical) and dual
channel emergency button.
Emergency Relay / Emergency Stop Relay Cat.4
12
DME Engineering - Consulting - Projects - Management
Phone: +55 11 4653-3124 / Cell Phone: +55 11 96734-2188
Electrical Diagram - Emergency Stop Relay
Electrical Diagram - Safety Relay
13
DME Engineering - Consulting - Projects - Management
Phone: +55 11 4653-3124 / Cell Phone: +55 11 96734-2188
Legal base
Condition Required by items 12.38 to 12.55 of the general provisions and Annex VI
Of NR-12.
Injection press mod. RT9-250Y20-A - Clasp type, vertical; Hydraulic drive; capacity
2450KN.
• Monitoring of Distance Actuators
4.4 Emergency Stop System
The equipment has 3 (three) emergency button, double channel monitored by
safety interface (Emergency Stop Relay), however, it was possible to identify if
emergency button identification base meets the NR12 requirement in items 12.56 to
12.63.1, as a facilitating recommendation for identification.
Emergency Button - Front Panel Power
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DME Engineering - Consulting - Projects - Management
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Emergency Button - Front Panel Power
Legal base
Condition required by Items 12.56 to 12.63.1 (emergency stop devices) of the general
provisions and Annex VI of NR -12
Injection press mod. RT9-250Y20 W-101/1 ODM6236 S1 - Type of closure, vertical;
Hydraulic drive; Closing force 91.6KN.
• Emergency Stop System
15
DME Engineering - Consulting - Projects - Management
Phone: +55 11 4653-3124 / Cell Phone: +55 11 96734-2188
RECOMMENDATION FOR CONDITION REQUIRED BY THE ITEMS 12.56 A
12.63.1 (emergency stop devices) of the general provisions and Annex VI of NR -12
• Replacement identification base in yellow / black letter and in
Portuguese, from the word EMERGENCY of Brazil, as a facilitating
recommendation for identification.
Emergency Button Plate
4.5 Manual Reset
The equipment has a reset button, however, it was possible to identify if it
meets the NR12 requirement in items 12.40 (safety system)
12.63 (emergency stop devices) of the NR-12 General Provisions.
Electrical Panel - Manual Reset Button
16
DME Engineering - Consulting - Projects - Management
Phone: +55 11 4653-3124 / Cell Phone: +55 11 96734-2188
Electrical Diagram - Reset Button Safety Relay
Electrical Diagram - Reset Button Emergency Stop Relay
17
DME Engineering - Consulting - Projects - Management
Phone: +55 11 4653-3124 / Cell Phone: +55 11 96734-2188
Legal base
Condition required by Item 12.40. (Safety system) and item 12.63 (emergency stop
devices) of the NR-12 General Provisions.
Injection press mod. RT9-250Y20 W-101/1 ODM6236 S1- Type of closure, vertical;
Hydraulic drive; Closing force 91.6KN.
• Manual Reset
RECOMMENDATION FOR CONDITION REQUIRED BY ITEMS 12.40.
(Safety system) and 12.63 (emergency stop devices) of the General Provisions of NR-
12.
• Installation of manual reset button (blue reset), ie unlocking the
emergency button can not enable the machine to be triggered without the
reset button being pressed.
• Reset button, current on the light curtain safety relay and also on the
emergency stop / door release and emergency button.
• If the equipment has 2 or more doors with a safety key and you want to
know which door is open, you can set a category 1 limit switch only to
indicate which door has been opened.
Manual Reset Button
18
DME Engineering - Consulting - Projects - Management
Phone: +55 11 4653-3124 / Cell Phone: +55 11 96734-2188
4.6 Electrical Panel / General Switch with Lockout for De-energization
The electrical panel has a locking access door, there is no safety warning and
identification of the internal circuits.
Electric panel
Legal base
Condition required by Items 12.118 and 12.119. (Signaling) of the General Provisions
Of NR-12.
Injection press mod. RT9-250Y20 W-101/1 ODM6236 S1- Type of closure, vertical;
Hydraulic drive; Closing force 91.6KN.
• Electrical Panel / General Switch with Lockout for De-energization
19
DME Engineering - Consulting - Projects - Management
Phone: +55 11 4653-3124 / Cell Phone: +55 11 96734-2188
RECOMMENDATION FOR CONDITION REQUIRED BY ITEMS 12.118 AND
12.119 (Signaling) of the General Provisions of NR-12.
• Placement of safety warning signs and identification of internal circuits.
• General key installation with lock.
Identification Cards
General Key with Lock
20
DME Engineering - Consulting - Projects - Management
Phone: +55 11 4653-3124 / Cell Phone: +55 11 96734-2188
4.7 Operation Signaling
Safety light signaling device to warn workers and others about the hazards they
are exposed to, operating and maintenance instructions and other information necessary
to ensure the physical integrity and health of workers.
Control Panel - Operation Signaling
Electric Diagram - Luminous Signaling Operation
21
DME Engineering - Consulting - Projects - Management
Phone: +55 11 4653-3124 / Cell Phone: +55 11 96734-2188
Legal base
Condition required by item 12.116 and 12.121 (Signaling) of NR - 12
Injection press mod. RT9-250Y20 W-101/1 ODM6236 S1- Type of closure, vertical;
Hydraulic drive; Closing force 91.6KN.
• Operation Signaling
4.8 Electrical and Hydraulic Manuals / Diagrams
The equipment manuals / electrical and hydraulic diagrams must
be written in Portuguese - Brazil.
https://drive.google.com/file/d/1CeAlYPj6BLuR7xrewRE5wgtQEMXDYR7J/view?usp=sharing
22
DME Engineering - Consulting - Projects - Management
Phone: +55 11 4653-3124 / Cell Phone: +55 11 96734-2188
Legal base
Condition required by Items 12.125 to 12.128 (Manuals) of the general provisions of
NR - 12.
Injection press mod. RT9-250Y20 W-101/1 ODM6236 S1- Type of closure, vertical;
Hydraulic drive; Closing force 91.6KN.
• Electrical and Hydraulic Manuals / Diagrams
4.9 Pressurized Components
Additional measures must be taken to protect hoses, pipes and other pressurized
components subject to possible mechanical impacts and other aggressive agents when
there is a risk.
23
DME Engineering - Consulting - Projects - Management
Phone: +55 11 4653-3124 / Cell Phone: +55 11 96734-2188
Legal base
Condition required by Items 12.77 to 12.84.1 (Pressurized Components) of the general
provisions of NR - 12.
Injection press mod. RT9-250Y20 W-101/1 ODM6236 S1- Type of closure, vertical;
Hydraulic drive; Closing force 91.6KN.
• Pressurized Components
RECOMMENDATION FOR CONDITION REQUIRED BY ITEMS 12.77 TO
12.84.1 (Pressurized Components) of General Provisions of NR-12.
• Hose protection installation
24
DME Engineering - Consulting - Projects - Management
Phone: +55 11 4653-3124 / Cell Phone: +55 11 96734-2188
5 Responsibilities
5.1 Preparation
Eng.º Glauton Machado Barbosa
5.2 Technical and Legal Responsible
Glauton Machado Barbosa
CREA/SP- 5.061.417.587/D
Project engineer
Inspector of CREA-SP
Full Member of the AEAAR Culture Council
Arujá, may 08, 2018
25
DME Engineering - Consulting - Projects - Management
Phone: +55 11 4653-3124 / Cell Phone: +55 11 96734-2188
5.3 ART
xxxxxxxxxxxxxxxxxxxxxxxxx xxxxxxxxxx
xxxxxx
xxxxx
xxxxx
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xxxxxxxxxxx
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xxxxxxxxxxxxx
26
DME Engineering - Consulting - Projects - Management
Phone: +55 11 4653-3124 / Cell Phone: +55 11 96734-2188