Modern Safety Systems Technology Utilization Presentation Chris Brogli - Ross Controls Global VP of Safety Business Development Manager chris.brogli@rosscontrols.com 1-859-595-9630 ROSS Controls The Global Leader in Fluid Power Safety Solutions
This morning we outlined the requirements of implementing fluid power safety solutions. Now we are going to dig a little deeper into how its done. Remember we said that IEC62061 X was intended for electrical, electronic and programmable electronic equipment. It can’t be used when fluid power safety is required. We are going to spend some time looking at each step in the process because most people don’t understand how to assess, select and implement fluid power safety solutions. ROSS Controls The Global Leader in Fluid Power Safety Solutions
In Europe the Machinery Directive defines the safety requirements that must be followed! ROSS Controls The Global Leader in Fluid Power Safety Solutions
Directives = Laws & Standards = Regulations ROSS Controls The Global Leader in Fluid Power Safety Solutions
Standards define the technical specifications that must be followed! IHS Standards : For access to the norms use IHS Standards (access see Peter Blanchard or Kerry White) ROSS Controls The Global Leader in Fluid Power Safety Solutions
The safety standards in Europe are called Functional Safety Standards Safety exists in order to protect.... People and Machines! Functional Safety looks at how well the safety system needs to function/perform! This is where the term safety functions come from. Remember we talked about structure, reliability & diagnostics. ROSS Controls The Global Leader in Fluid Power Safety Solutions
There are 3 levels of standards! Type A, B & C • Two examples we will discuss are: – North America – OSHA Requirements – European – Machinery Directive Requirements • There are three types of Standards – “A” Standards (Basic Standards) • basic concepts • principles for design • general aspects – “B” Standards (Application Standards) • B1 - safety distances, surface temps, noise • B2 - components or devices – “C” Standards (Specific Machine Standards) • Vertical standards covering a single type of machine or group of machines. • Use A and B standards to create C standards. ROSS Controls The Global Leader in Fluid Power Safety Solutions
European/International Standards - EN, ISO and IEC EXAMPLES: Type A General Requirements & Principles ISO 12100 Safety of machinery. Basic terminology and methodology ISO TR14121-2 Safety of machinery — Risk assessment — Part 2: Practical guidance and examples of methods Type B Specific Technology Requirements ISO 13849-1 - Safety related parts of control systems IEC 62061 - Functional safety of electrical, electronic and programmable electronic control systems IEC 60204-1 - Safety of machinery and Electrical Equipment Type C Machine Specific Requirements EN1114 – Machines for rubber and plastic materials – Extruders – Safety Prescriptions EN12013 – Machines for rubber and plastic materials – Internal Mixers – Safety Prescriptions ROSS Controls The Global Leader in Fluid Power Safety Solutions
The Machinery Directive says that risk assessments have to be done! ANNEX I Essential health and safety requirementsrelating to the design and construction of machinery GENERAL PRINCIPLES 1. The manufacturer of machinery or his authorized representative must ensure that a risk assessment is carried out in order to determine the health and safety requirements which apply to the machinery. The machinery must then be designed and constructed taking into account the results of the risk assessment. ROSS Controls 9 The Global Leader in Fluid Power Safety Solutions
I like to think of safety as a lifecycle….. 1. Assessment 5. Maintain & Improve The Machinery Safety Life-cycle! 4. Installation & Validation 2. Functional Requirement Specification 3. Design, Selection & Verification ROSS Controls The Global Leader in Fluid Power Safety Solutions
Remember we said that the first part of ISO12100 outlines the risk assessment process. Assessment Determine the Limits Identify the Hazards Estimate the Risk Evaluate the Risk ROSS Controls The Global Leader in Fluid Power Safety Solutions
Since harm can come from multiple sources in each mode of operation. • Each mode should be evaluated – Auto/Manual/Jogging/Threading • Each type of task should be evaluated – Production – Loading/Unloading/Adjusting – Set-up – Change-overs/Teaching – Maintenance – Service/Repairs/Replacement/Lube – Material Handling – Loading/Unloading – Sanitation – Cleaning/Washing Every mode and every task must be evaluated in order to identify all of the hazards. ROSS Controls The Global Leader in Fluid Power Safety Solutions
The reason for using a multi-functional team to ensure identification of all hazards. On average, 60 to 70% of all injuries happen outside normal production activities! The problem is that most assessments only evaluate automatic or normal operations. Source: International Labor Organization OSHA did a similar study and showed similar results. ROSS Controls The Global Leader in Fluid Power Safety Solutions
Yesterday we said that we should use the ISO13849 when designing fluid power safety solutions so we are going to do the assessment according to ISO13849. ROSS Controls The Global Leader in Fluid Power Safety Solutions
Let’s assume that we are evaluating a hydraulic metal forming press that punches holes in sheets of steel. The injury would be an amputation if you were caught in the press. + The press has to be loaded & unloaded every 15 seconds. + The press moves at a speed of less than 250mm/sec. = This would result in a Required Performance Level of d (PLd) ROSS Controls The Global Leader in Fluid Power Safety Solutions
A step that many companies skip is mapping the job tasks to determine where they fall. This will help in the development of the specification. Maintenance, service and repair tasks require the use of Lock-out & Tag-out. Minor servicing tasks that are routine, repetitive and integral to the operation of the equipment can use alternative methods of control . Normal machine operations can use safeguarding methods. Most risk assessments do not identify and categorize risks associated with job tasks. They simple identify and quantify risk levels. ROSS Controls The Global Leader in Fluid Power Safety Solutions
This is an example of how a “Best in Class” company is mapping their job tasks to identify where they fall in order to understand how to treat them! Machine Maintenance, Service & Normal Production Operations Repair Tasks • Regulation: Machine Guarding or • alternative protection means Regulation: Lock-out / Tag-out or • Energy Isolation Requirement: Protect operators from • machine production hazards Requirement: Release stored energy • • Tasks: Operator Interaction for Regular Tasks: Service and Maintenance Machine Production Minor Service Must provide alternative Exception to Lockout Tagout Measures that offer effective protection Minor Servicing Activities • minor jams, minor tool changes & adjustments, exchange • Regulation: Machine Guarding, alternative protection means and procedures • Requirement: Protect operators from machine production hazards when performing minor servicing • Tasks: Minor servicing such as clearing f work piece, etc. Minor servicing must be routine, repetitive and integral to the operation of the system. ROSS Controls The Global Leader in Fluid Power Safety Solutions
Step 2 is developing the functional specification that determines how the machine will operate. 1. Assessment 5. Maintain & Improve The Machinery Safety Life-cycle! 4. Installation & Validation 2. Functional Requirement Specification 3. Design, Selection & Verification ROSS Controls The Global Leader in Fluid Power Safety Solutions
This is where the Second part of the ISO1200 and ANSI B11.0 come into play. Risk Reduction Reduction by Design Measures Reduction by Guarding Reduction by Safeguards Reduction by Information ROSS Controls 19 The Global Leader in Fluid Power Safety Solutions
They are mapping the tasks and are using the hierarchy of risk reduction measure to determine the best solutions. Hierarchy of Protective Measures Many people say that LOTO is a form of Elimination elimination because it eliminates energy! Fixed Guarding Elimination Engineered Safeguards Fixed Guarding Engineered Safeguards Awareness Means, Training and Procedures (Administrative) Warning Administrative Controls PPE DEFEATIBILITY Personal protective equipment ROSS Controls 20 The Global Leader in Fluid Power Safety Solutions
Let’s look at the risk reduction hierarchy in common terms. Original Hazard Awareness Elimination (Signs/Training/Procedures PPE ) Guarding & Access Control ROSS Controls The Global Leader in Fluid Power Safety Solutions
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