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1 Optima o In control since 1995 Safety Update This presentation covers Machinery Directive 2006/42/EC BS/EN954-1 EN ISO 13849-1 EN/IEC 62061.

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Presentation on theme: "1 Optima o In control since 1995 Safety Update This presentation covers Machinery Directive 2006/42/EC BS/EN954-1 EN ISO 13849-1 EN/IEC 62061."— Presentation transcript:

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2 1 Optima o In control since 1995 Safety Update This presentation covers Machinery Directive 2006/42/EC BS/EN954-1 EN ISO EN/IEC 62061

3 2 Optima o In control since 1995 Introduction Machinery Directive 2006/42/EC Process of Risk Assessment EN ISO 12100–2:2003 Safety of Machinery.Technical principles Machine manufacturers are obligated to complete a Risk Assessment that is now defined within the directive as an iterative process of hazard identification, risk estimation, hazard elimination or risk reduction. Safety system requirements Machine designers are obligated to design control systems in such a way that a fault in the hardware or software of the control system and/or reasonably foreseeable human error does not lead to hazardous situations

4 3 Optima o In control since 1995 Current status BS/EN954-1 Valid up to 29th December 2009 (Update from beginning September 09: EN954-1 has been given a stay of execution until the end of 2011) EN ISO is applicable for electrical/electronic/programmable electronic/hydraulic/pneumatic/mechanical systems. EN/IEC is applicable for electrical/electronic/programmable electronic systems

5 4 Optima o In control since 1995 Usage of different standards BS/EN954-1 was used for all safety systems using standard control circuits and tried and tested equipment. Higher levels of safety achieved by monitoring at various stages, once per shift, every reset etc. EN ISO is applicable for: electrical/electronic/programmable electronic/hydraulic/pneumatic/mechanical systems. EN/IEC is applicable for electrical/electronic/programmable electronic systems

6 5 Optima o In control since 1995 Safety Categories EN945-1 S severity of injuryS1 slight (normally reversible injury) S2 serious (normally irreversible injury or death) F frequency and/or exposure to hazardF1 seldom-to-less-often and/or exposure time is short F2 frequent-to-continuous and/or exposure time is long P possibility of avoiding hazard or limiting harm P1 possible under specific conditions P2 scarcely possible BS/EN954-1 Categories B,1,2,3,4

7 6 Optima o In control since 1995 Safety Categories EN EN ISO Performance Levels a-e S severity of injuryS1 slight (normally reversible injury) S2 serious (normally irreversible injury or death) F frequency and/or exposure to hazardF1 seldom-to-less-often and/or exposure time is short F2 frequent-to-continuous and/or exposure time is long P possibility of avoiding hazard or limiting harm P1 possible under specific conditions P2 scarcely possible

8 7 Optima o In control since 1995 Safety Categories EN62061 IEC/EN is the machine sector specific standard within the framework of IEC/EN EN is harmonised under the European Machinery Directive. The Safety Integrity Level (SIL) is the new measure defined in IEC regarding the probability of failures in a safety function or a safety related system. For machinery, the probability of dangerous failures per hour of a control system is denoted in IEC/EN as the PFH d

9 8 Optima o In control since 1995 Safety Categories EN62061 EN/IEC requires each safety function to be assessed in the following manner The required risk assessment graph is shown on the following pages Risk related to the identified hazard Severity of the possible harm =and Frequency and duration of exposure Fr Probability of occurrence of a hazardous event Pr Probability of avoiding or limiting harm Av Probability of occurrence of that harm } Se

10 9 Optima o In control since 1995 List all the possible hazards of the machine and Determine the parameters according to the tables and fill in the values: The Class Cl is the sum of: Fr + Pr + Av = Cl Safety of Machinery and Functional Safety Machinery: Risk parameter examples of IEC/EN 62061

11 10 Optima o In control since 1995 Safety of Machinery and Functional Safety ++= Example according to IEC/EN Machinery: Determination of the required SIL (Safety Integrity Level).

12 11 Optima o In control since 1995 Machinery: Risk assessment form given as an example in IEC/EN 62061

13 12 Optima o In control since 1995 Safety Level Comparison SIL calculations can be approximately converted over to PL levels… The relationship between the categories, the PL and the SIL is as follows: Not more than 1 dangerous failure of the safety function in 100 years Not more than 1 dangerous failure of the safety function in 1000 years Not more than 1 dangerous failure of the safety function in 10 years

14 13 Optima o In control since 1995 Calculation of PL and SIL To enable the value of PL or SIL to be calculated information must be available from equipment manufacturers. Software Packages available to help with verification of PL or SIL PILZ Pascal SIEMENS The Safety Evaluation Tool online package SISTEMA German BGIA organisation tool for calculating Performance Level to EN ISO FREE! £ £

15 14 Optima o In control since 1995 Calculation of PL and SIL Example calculation - Risk assessment for a rotary printing machine On a web-fed printing press, a paper web is fed through a number of cylinders. High operating speeds and rotational speeds of the cylinders are reached, particularly in newspaper printing. Essential hazards exist at the zones where it is possible to be drawn in by the counter-rotating cylinders. This example considers the hazardous zone on a printing machine on which maintenance work requires manual intervention at reduced machine speeds. The access to the hazardous zone is protected by a guard door (safeguarding). The following safety functions are designated: SF1 Opening of the guard door during operation causes the cylinders to be braked to a halt. SF2 When the guard door is open, any machine movements must be performed at limited speed. SF3 When the guard door is open, movements are possible only whilst an inching button is pressed. Example taken from BGIA report 2/2008e Entrapment between the cylinders causes severe injuries (S2). Since work in the hazardous area is necessary only during maintenance tasks, the frequency and duration of hazard exposure can be described as low (Fl). At production speeds, no possibility exists of avoiding the hazardous movement (P2).

16 15 Optima o In control since 1995 Calculation of PL and SIL Example calculation - Risk assessment for a rotary printing machine Example taken from BGIA report 2/2008e This therefore results in a required Performance Level PL r Of d for the safety functions SF1 and SF2 The safety function SF3 can however be used only if the printing machine has first been halted (SF1) and the permissible rotational speed of the cylinders limited (SF2). This results in the possible machine movements being predictable for the operator, who is thus able to evade hazardous movements (P1). A required performance level PL r of c is therefore adequate for SF3.

17 16 Optima o In control since 1995 Conclusions EN ISO is the default choice for systems that contain non-electrical systems and an overall summary is shown below:


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