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Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
PUBLIC INFORMATION
SF10 – What is Your Safety Skill Set
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Agenda
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Other Resources
Safety Life Cycle
OSHA and Standards Compliance
Why Implement Machinery Safety
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Why companies implement machinery safety solutions & programs.
Protect employees Protect employees from unsafe conditions
Protect employees from know hazards
Reduce costs Reduced Medical & Insurance expenses
Regulatory Compliance Regional or International
Protect their Brand Bad publicity causes reduced sales
To improve productivity Limited machine shut down Vs. stopping completely
Reduced occurrence for full system lockout/tagout
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Agenda
Add Agenda Items Here
Other Resources
Safety Life Cycle
OSHA and Standards Compliance
Why Implement Machinery Safety
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
OSHA CFR 1910 Standards
CFR 1910.147 – Lockout / Tagout Standard
Applies when employees perform maintenance and service to production equipment
Requires that unexpected energization of equipment be prevented by removing all energy from a machine
and locking the energy sources in the off-state whenever an employee must place any part of their body in
a potentially hazardous location
CFR 1910 Subpart O – Machine Guarding Standards
Applies when employees operate and work around equipment that is in the production state
Requires that employers provide safeguarding of hazards that could cause injury or illness to employees
Exception to Lockout/Tagout
Applies when employees perform “minor servicing” to equipment
Requires that employers provide effective “alternative measures” to safeguard employees
Question: What OSHA standards apply to machine guarding of production equipment?
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Relationship of OSHA Standards
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
If machine access is required, 2 choices:
Lock-out/Tag-out - Energy
Isolation
Alternative means – Machine
Safety
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
OSHA Connection
National Consensus
Note: These are NOT OSHA regulations. However, they do provide guidance
from their originating organizations related to worker protection.
American National Standards Institute (ANSI)
RIA R15.06-2012, Industrial Robots and Robot Systems - Safety Requirements
ANSI B11.19:-1990, Machine Tools, Safe Guarding
International Standards Organization (ISO)
EN ISO 13849-1:2006 Safety of machinery - Safety-related parts of control systems
OSHA lists National Consensus, that provide guidancehttps://www.osha.gov/SLTC/robotics/
https://www.osha.gov/Publications/Mach_SafeGuard/chapt5.html
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
EN/ISO and OSHA/ANSI Standards Hierarchy Comparison
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Agenda
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Add Agenda Items Here
Safety Life Cycle
OSHA and Standards Compliance
Why Implement Machinery Safety
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Functional Safety Design Process - the “Safety Life Cycle”
The Machinery Safety Lifecycle is a defined process that is followed to ensure that proper safety practices have been implemented!
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
The Purpose of Risk Assessment
12
Properly identifies and assesses the real hazards involved in operating a particular machine.
Determines equivalent levels of protection for safeguards when stating OSHA’s minor service exception.
Takes away guesswork when estimating risk and prescribing safety system performance.
Serves as documented proof of your “due diligence”.
Establishes the foundation for the design and implementation of an effective machine safety program.
The risk assessment process:
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Risk Assessment: Determine the Level of Risk and Safety Preformance Required
Risk Assessment Process ISO12100 Risk Graph 13849-1 Annex A
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Methodology and Risk Graph per RIA TR R15.306-2014
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Example of Risk Scoring System quantification - HRN
15
There are numerous ways of assessing risk involved with a hazard, one of which is the Hazard Rating Number system.
In this technique, numerical values are assigned to descriptive phrases
relating to... The likelihood of occurrence (LO) of coming into contact with the hazard
The frequency of exposure (FE)
The degree of possible harm (DPH)
The number of persons at risk (NP)
A Hazard Rating Number is completed using the following calculation:
LO x FE x DPH x NP = HRN
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Hazard Rating-Number HRNRisk Assessment Calculator
LO (Likelihood of Occurrence) Probable 8
FE (Frequency of Exposure) Daily 2.5
DPH (Degree of Possible Harm) Break of minor bone or minor illness (temporary) 2
NP (Number of Persons at risk) 3-7 persons 2
Hazard Rating Number: HRN: 80
HRN Risk
0-5 Negligible
5-50 Low, significant
50-500 High
over 500 Unacceptable
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Functional Safety Design Process - the “Safety Life Cycle”
The Machinery Safety Lifecycle is a defined process that is followed to ensure that proper safety practices have been implemented!
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Functional Specification
18
Safety Function - function of the machine whose failure can result in an
immediate increase of the risk(s)
System components include
Input
Logic
Output
For each safety function, the characteristics (see Clause 5) and the
required performance level shall be specified and documented in the
safety requirements specification. (13849-1 4.2.2)
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Safety Function Documents
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Safety Functional Specification
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Functional Safety Design Process - the “Safety Life Cycle”
The Machinery Safety Lifecycle is a defined process that is followed to ensure that proper safety practices have been implemented!
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Selection, Design, and Verification
Design considerations:
What mitigation technique should I use?
What circuit structure should I use?
What safety products should I use?
What type of control system should I use?
What type of special operations do I need?
Where are all of my safety devices?
What kind of interactions are needed for auxiliary
machines?
What kind of diagnostics do I need?
Should I use hardwiring or networked systems?
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Safety Automation Builder
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Verification and Validation
24
Verification and validation play important roles in the avoidance of faults throughout the safety system design and development process. ISO 13849-2 sets the requirements for verification and validation. The standard calls for a documented plan to confirm that all of the safety functional requirements have been met.
Verification is an analysis of the resulting safety control system. The Performance Level (PL) of the safety control system is calculated to confirm that the system meets the required Performance Level (PLr) specified. The SISTEMA software is typically used to perform the calculations and assist with satisfying the requirements of ISO 13849-1.
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
SISTEMA
Safety Integrity Tool for
the Evaluation of
Machine Applications
Used to model
each Safety
Function and
Evaluates the
Performance Level
Achieved. (PL)
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Functional Safety Design Process - the “Safety Life Cycle”
The Machinery Safety Lifecycle is a defined process that is followed to ensure that proper safety practices have been implemented!
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Installation, Verification & Validation
27
Validation is a functional test of the safety control system to demonstrate that the system meets the specified requirements of the safety function. The safety control system is tested to confirm that all of the safety-related outputs respond appropriately to their corresponding safety-related inputs. The functional test includes normal operating conditions in addition to potential fault injection of failure modes. A checklist is typically used to document the validation of the safety control system.
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Validation Checklist (V&V Plan)
ISO 13849-2 sets the requirements for verification and validation.
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Validation Checklist (V&V Plan)
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Functional Safety Design Process - the “Safety Life Cycle”
The Machinery Safety Lifecycle is a defined process that is followed to ensure that proper safety practices have been implemented!
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Operate, Maintain & Improve
Periodic testing should be done to verify
proper system functionality.
Machine modifications that affect safety
require validation of the safety function
Program changes
Safety system use
Hardware or software changes
Machinery changes
Should the safety-related software be subsequently modified, it shall be revalidated on an appropriate scale.
ISO 13849-2, 9.5
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Agenda
Add Agenda Items Here
Other Resources
Safety Life Cycle
OSHA and Standards Compliance
Why Implement Machinery Safety
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Safe Book 4 Reference Booklet
http://literature.rockwellautomation.com/idc/groups/lit
erature/documents/rm/safebk-rm002_-en-p.pdf
Safety related control systems for machinery
Regulations
Standards
Safety Strategy
Protective Measures
Safe Distance Calc
Unexpected Startup
SRP/CS & FS
Design per 13849-1
Design per 62061
Safety Related
Control Systems;
Structure
SISTEMA
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
TÜV Rheinland ; Technicians Course
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
TÜV Rheinland ; Functional Safety for Machinery
Introduction
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
TÜV Rheinland ; Functional Safety for Machinery
Engineer Certification
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Safety Portal
http://marketing.rockwellautomation.com/safety-solutions/en/
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
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