T63 - Safety System Development Process and … · Basic Safety Assessment or ... Awareness Means,...

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900D

T63 - Safety System Development Process and Configuration Tools Overview

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Session Purpose and Intent

This session is meant to outline the steps of developing machinery

safety solutions and tools that can help reduce the time to design,

develop, implement and start up a machinery safety system.


Agenda

3

Closing & Wrap-up

Sample Project Utilizing the tools

Selection, Design, Verification, Development & Justification Tools

Safety Life-cycle Utilization

Safety System Development Process



4

Common Safety System

Development Process

Machine review & hazard

identification

Product Selection

Safety System Design

Safety System Installation

Start Production

Proper Safety System Development Process

Risk Assessment

Functional Specification Development

Product Selection

Structure Selection

Safety System Design

Design Verification

Safety System Installation

Verification & Validation

Training

Start Production

Operation & Maintenance


Most people use the common approach!

5

Most people only analyze automatic operations!

Fact – 60 to 70% of all injuries occur outside of normal production activities.

Most people identify hazards and immediately select safety

devices/solution without considering the effects on productivity!

The number 1 cause of safety system failures is because the solution is

bypassed. This happens because it was not designed to accommodate job

tasks.

Most safety systems that follow the common process result in

significant reductions in equipment utilization!

Most people have never been to a training session or have never read a machinery safety standard! This results in safety systems that are inadequate, ineffective & improperly designed.


Agenda

6

Closing & Wrap-up






The Rockwell Automation approach follows the “Safety Life Cycle”

7

1. Assessment

The Machinery Safety Lifecycle is a defined process that is followed to ensure that proper safety practices have been implemented!

5. Operate, Maintain & Improve

4. Installation & Validation

2. Functional Requirements

3. Selection, Design & Verification

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 8

Step 1 in the Machinery Safety Lifecycle is the

Assessment!


1. Assessment




Proper safety system development starts here!


What is an assessment and how do I do it?

Step 1: The assessment.

The foundation of safety system development!

Machine Characteristics/Limits

Risk Evaluation

Hazard Identification

Risk Estimation

Risk Reduction

Risk Tolerable

OK

Too High

Risk Assessment Process according to ISO12100 and ANSI BB.0


The Proper Approach: A standards based methodology!

10

Both EN, ISO and ANSI standards require a systematic approach for safety

system development!

So which standard is right for you?

S1

S2

E1

E2

R1

A1

A2

A1A2

A1A2

A1

E1

E2R2A

R2B

R2B

R2C

R3A

R3B

R4

S1

S2

F2

F1

a

b

P1

P2

e

c

d

P1

P2P1

P2P1

P2

F2

F1

b

c

d

OR

ANSI/RIA Method EN/ISO Method

Either is OK but the move is towards the ISO methods to global use. ANSI recognizes ISO and IEC standards today. This allows OEM’s to have 1 design for worldwide use!


Rockwell Automation uses 3 Scalable Assessment Solutions

Copyri

ght ©

11Conformity Audits Guarding Evaluation Risk Assessments

Multiple Machines / Plant Wide

Machine Audit

Identifies Primary Guarding

Hazards

Basic Safety Assessment or

Team Based Risk Assessment (TBRA)

Provides a High Level Analysis of

Specific Safety Areas

Identifies guarding hazards for

immediate plant actions

Basic Safety Assessment - provides analysis using limited customer personnel

Team Based Risk Assessment - In-depth analysis required for critical or special machines

Provides a high level safety analysis

of machine by performing the

following:

Conformity audit that analyzes

guarding, components that

perform a safety function, e-

stops, LOTO and / or isolation

devices are identified and labeled

Existing safety circuit estimation

Provides a method for identifying

conforming and non-conforming

machinery.

Provides a method to prioritize

machines for further assessment

Provides a rapid approach to

identifying point-of-operation and

power transmission hazards and

identifying appropriate and effective

safeguarding measures for

reducing risk and exposure

Report Identifying

Hazard exposure

Category / Performance level

per standards

Potential safeguard or risk

mitigation solution

Basic Assessment - provides analysis using limited customer personnel

Assessment by RA Safety Engineer / Consultant, limited customer involvement. (Typically operations /

maintenance)

Assessment report includes:

- Documentation of participants

- Identification of primary hazards / tasks

- Risk In / Risk Out Rating

- Recommendations for safety

improvements, such as:

• Protective Guarding; Electrical Safety Controls; Pneumatic / Fluid Power Safety Controls

Safety circuit performance requirements

Photograph of critical identified hazards (based on customer approval)

Team Based Risk Assessment - In-depth analysis required for critical or special machines

All features of the Basic Safety Assessment plus the following additional features:

Team-based assessment facilitated by RA Safety Engineer / Consultant

Customer team typically consist of operations, maintenance, engineering, technicians, cleaning, sanitation &

safety personnel

Basic risk assessment training

Hazard identification during setup, normal and abnormal operation, sanitation / cleaning, maintenance (under

limited energy), emergency conditions

Report documentation includes all elements from Safety Evaluation with additional information:

- Plan view machine layout with recommended safety improvements

- Limits of machine

- Incident/accident history

- This service can satisfy the risk assessment requirements of safety

standards (i.e. OSHA, ANSI, CE Machinery Directive, …)



1. Assessment




Step 2 in the Machinery Safety Lifecycle is the safety

requirements specification!

The SRS defines the functional requirements of the safety system!



1. Assessment




Step 3 is the selection, design & design verification phase.

This step focuses on safety system design, product selection, circuit selection and design verification!


My assessment & requirements spec sure made this easy!

The design phase includes selection of mitigation techniques,

products, circuit designs & system structure determination!

Design considerations:• What mitigation technique should I use?• What products allow this functionality?• What circuit structure should I use?• What type of control system should I use?

(Relays/Controllers/PLC’s)• What type of special operations do I need?

(Zone control/Safe-speed/etc.)• 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?

The following slides are going to take a deeper look!

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

15

Possible Mitigation Techniques!

Design it out

Fixed enclosing guard

Monitoring Access /

Interlocked Gates

Awareness Means, Training and Procedures

(Administrative)Personal protective

equipment

Most Effective

Least Effective

Hierarchy of Protective Measures


Product Selection Options!

The risk assessment tool identified the required performance level and

Category that is required for each part/portion of the machine. Use

products that meet the required performance level (PLr) and/or the

Category level as directed by the risk assessment.

Note: A safety system is made up of the following components:

Safety input devices/actuators

Safety control/logic devices

Safety output devices

Remember your weakest link sets your maximumsystem performance that can be achieved!


A complete safety solution is made up of combinations of input, logic and outputs!

Out complete portfolio is our key differentiator.

Glo

bal M

arket

Lead

ers

Light C

urtain

Laser Scan

ne

r

Cam

era

No

n-C

on

tact (RFID

)

Ke

y Inte

rlock

Ple

Lockin

g

Trap K

ey

Mats

Edge

s

Enab

ling

Two

-Han

d P

B

Cab

le P

ull

E-Stop

Re

lays

Co

nfigu

rable

PLC

DIO

Co

ntacto

rs

Drive

s

Servo

Mo

tion

Valve

s

Ind

icators

Info

rmatio

n le

vel

Co

mp

on

en

t leve

l

Cab

les &

Distr. B

locks

#1

Rockwell

#2

#3

#4

#5

Fully capable Offered but limited

No offering Offered through partner

Input Devices Logic Devices Output DevicesNetwork &

Connectivity


We also have the most Scalable Safety Logic Solutions in the market.

Integration Continuum

Offering solutions that fit your needs, not ours!

Basic Safety Solutions Modern Safety Solutions Contemporary Solutions

Low High

Simple connectivityMechanical linked machine

Stand alone machineLow cost

Just enough control

Multi-axis motionIncreased controller capabilities

Mix of mechanical and electrical controlsLow engineering costs

Coordinated multi-axis motionRobotic feeders

Electronic line shaftingAdvanced connectivity

Advanced information capabilities

1818Copyright © 2011 Rockwell Automation, Inc. All rights reserved.


Safety Relay/Safety Controller/Safety PLC Selection Matrix!

Safety Relays• 1 Zone• Local/Hardwired I/O• Simple Safety Logic• 1 to 2 dual channel Inputs• 2 to 3 outputs• Little to no motion

Safety Controllers & Expandable Relays• 1 to 3 Zones• Local & Distributed I/O• Simple & Complex Safety Logic• 1 to 10 dual channel Inputs• 1 to 10 outputs• Basic Diagnostics thru PLC• Up to 6 axes of motion

Safety PLCs• More Than 3 Zones• Distributed I/O• Semi-complex & Complex

Safety & Standard Logic• 1 to 100 dual channel Inputs• 1 to 100 outputs• Advanced HMI Diagnostics• Multiple axes of motion


Safety Output Selection Matrix

Safety Contactors & Relays• Simple on/off control• Power control• Signal control

Safety Variable Frequency Drives• On/off control with the ability

to control & monitor speed

Safety Servo Systems• On/off control• Speed control• Direction control• Position control• Location control• Acceleration control• Decceleration control


How do I verify my design!

The design phase also includes design verification!

Design verification considerations:• What is meant by system structure?• What is system reliability?• What is diagnostic coverage?• Where do I get the product safety data?• What verification tool should I use?


The 1st design Verification Consideration is

what types of structure are you going to use?

22Copyright © Rockwell Automation, Inc. All rights reserved.

CAT B/1 CAT 2

CAT 3 CAT 4 (higher diagnostic coverage that CAT 3)


The 2nd and 3rd steps of design verification includes

calculating the MTTFd and DC of the system.

23

MTTFd Mean Time to Dangerous FailureLow 0 -10 YearsMedium 10-30 YearsHigh 30-100 Years

DC Diagnostic Coverage = Detected Dangerous Failures / All Dangerous Failures

None DC < 60%Low 60 < DC < 90%Medium 90 < DC < 99%High DC >99%

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. 24

a

b

c

d

ePer

form

ance

Lev

el

Designated

Architecture

Designated

Architecture

Designated

Architecture

Designated

Architecture

Designated

Architecture

Designated

Architecture

Designated

Architecture

Cat B Cat 1 Cat 2 Cat 2 Cat 3 Cat3 Cat 4

DC avg DC avg DC avg DC avg DC avg DC avg DC avg

<60% <60%

60% to <

90%

90% to <

99%

60% to <

90%

90% to <

99% 99%

Structure (Category)

Diagnostic Coverage (DC)

Reliability (MTTF)

Confirming PL is achieved by…Balancing Structure (Cat), Reliability (MTTFd)

and Diagnostic Coverage (DCavg)



1. Assessment




The next phase includes validating that the safety

system operates as intended.

This step focuses on ensuring that the safety system was installed properly and that there is a defined process for validating system performance!



1. Assessment




The final step covers Operation & maintenance to

ensure that the system remains functional

Step 5 focuses on ensuring that the safety system is operated properly and maintained to ensure continued effectiveness!



1. Assessment




The Machinery Safety Lifecycle Never Ends!

The circle never ends. The system must be re-evaluated anytime modifications occur and each step must be followed!


Agenda

28

Closing & Wrap-up






Another way of doing Design Verification is using a software called SISTEMA

29

SISTEMA is a free design verification tool that isinternationally recognized!


Rockwell created a new safety selection tool that utilizes SISTEMA for verification

30

SAB utilizes SISTEMA for design verification but simplifies theprocess by using menus and questions to help with selection!


Rockwell Automation’s investment in tools!

Safety Return-On-Investment ToolFind out how to quantify the savings and productivity gains from safety investments. The Rockwell Automation Safety Return-On-Investment Tool accounts for improved safety, reduced claims, improved productivity, and other issues unique to safety applications.

Safety Functions

Safety Functions ProgramThe Safety Functions Program is building block approach to designing safety systems. Each building block has a complete documentation package that includes a description of each safety function, an electrical schematic, a bill of material, a SISTEMA verification calculation and a verification and validation plan.

SABSafety Automation BuilderThe Safety Automation Builder software package that allows users to import images of their machines. Users can identify hazardous access points and the associated hazards in order to develop a list of safety products that will be used to mitigate the risk. This gives the customer a complete drawing, a bill of material and SISTEMA calculation.

Safety Accelerator

Toolkit

Safety Accelerator Toolkit This toolkit provides easy to use system design, programming, and diagnostic tools to assist you in the rapid development and deployment of your safety systems using GuardLogix, Compact GuardLogix, or SmartGuard 600 Controllers, Guard I/O, and Safety Devices. The toolkit includes a risk assessment and system design guide, hardware selection guide, CAD drawings, safety logic routines, and operator status and diagnostic faceplates.

Connected Components

BB

Connected Components Building BlocksThese building blocks are tools that help customers develop safety solutions that utilize component class safety solutions. These building blocks include sample programs, electrical schematics and configuration document that help in the

ProSafeBuilder

ProSafe BuilderThe ProSafe Builder software gives users the ability to layout complete trapped key solutions for machinery safety applications with a tool that generate a bill of material and system configuration schematic/map.

The broadest suite of safety tools in the industry!

http://safetyroi.avidcom.com/




Safety System Development Tools

32

SABSafety Automation BuilderThe Safety Automation Builder software package that allows users to import images of their machines. Users can identify hazardous access points and the associated hazards in order to develop a list of safety products that will be used to mitigate the risk. This gives the customer a complete drawing, a bill of material and SISTEMA calculation.

ProSafeBuilder

ProSafe BuilderThe ProSafe Builder software gives users the ability to layout complete trapped key solutions for machinery safety applications with a tool that generate a bill of material and system configuration schematic/map.


What is Safety Automation Builder (SAB)?

SAB is a new tool designed to help develop complete safety system solutions. These solutions include conceptual layout drawings that includes zones, physical guards, hazards, access points and the products used to protect personnel.


Safety System Investment Justification Tool

34

Safety Return-On-Investment ToolFind out how to quantify the savings and productivity gains from safety investments. The Rockwell Automation Safety Return-On-Investment Tool accounts for improved safety, reduced claims, improved productivity, and other issues unique to safety applications.





ROI Example Output!

35

The Safety ROI tools helps customers justify safety projects based on

project cost and injury avoidance calculations!


Safety System Design Tools

36

Safety Functions

Safety Functions ProgramThe Safety Functions Program is building block approach to designing safety systems. Each building block has a complete documentation package that includes a description of each safety function, an electrical schematic, a bill of material, a SISTEMA verification calculation and a verification and validation plan.

Safety Accelerator

Toolkit

Safety Accelerator Toolkit This toolkit provides easy to use system design, programming, and diagnostic tools to assist you in the rapid development and deployment of your safety systems using GuardLogix, Compact GuardLogix, or SmartGuard 600 Controllers, Guard I/O, and Safety Devices. The toolkit includes a risk assessment and system design guide, hardware selection guide, CAD drawings, safety logic routines, and operator status and diagnostic faceplates.

Connected Components

BB

Connected Components Building BlocksThese building blocks are tools that help customers develop safety solutions that utilize component class safety solutions. These building blocks include sample programs, electrical schematics and configuration document that help in the


Safety Functions are the building blocks of machinery safety solutions!

Risk Assessment Model & Confirm PLr

Determines (PLr) Confirms PLr Achieved


The more complicated the machine the mores safety functions you need!

E-Stop Device 1

E-Stop Device 2

Light Curtain 1

Door Interlock 1

Logic

Output 1

Output 2

Output 3

SF1

SF2

Logic

SF3

SF4 Output 4Logic

Logic

Large and complex machines may require multiple safety functions to provide a complete machine safety solution. Safety function documents are 1 way that Rockwell Automation can help!

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. 39

Safety Function Documents

Safety Function: Emergency Stop Products: Light Curtain / GuardLogixSafety Rating: PLe, Cat. 4 to EN ISO 13849.1 2008

.

IntroductionImportant User InformationGeneral Safety InformationSafety Function RealizationSetup and WiringConfigurationProgrammingFalling Edge ResetCalculation of PFHdVerification and Validation PlanAdditional Resources


IA Safety Accelerator Toolkit

Development Tools and Quick Start Guide

Simplified Wiring

Preconfigured Logic

Quick Start Manual

Preconfigured HMI


Connected Component Building Blocks for Safety

41

Pre-designed Building Blocks with source code, drawings and quick-start guide to help you develop safety solutions!


Agenda

42

Closing & Wrap-up






Let’s look at a sample machine!

43

We are going to use the safety tools to develop a safety solution utilizing

Safety Automation Builder. This will leave us with a concept drawing, a

design verification and a complete bill of material.

We will use the ROI tool to help the customer justify the project.

We will then search for solutions for the selected products using safety

functions, safety accelerator toolkit and connected components building

blocks.


Machine Description

44

Infeed Conveyor

OutfeedConveyor

Rotary Table

Label P&P

Label Feeder

Hot Glue GunProduct


Step 1 – Risk Assessment

45

We are going to develop a risk assessment utilizing the ISO12100

evaluation method.

S1

S2

F2

F1

a

b

P1

P2

e

c

d

P1

P2P1

P2P1

P2

F2

F1

b

c

d


Step 1 Details

46

Normal operation

Maintenance

Set-up

Adjustment

Change-over

Start-up

Decommissioning

Etc.

Identify the hazards and associated risks! Develop a functional specification that outlines how each hazard needs to be protected for each mode of operation.

Thermal Hazard

Crushing Hazard

Pinching Hazard

Pinching Hazard

It is estimated that 60 to 70% of all injuries happen outside of normal production activities

yet most people spend 90% of their efforts around designing for production activities!


Step 2: Write a Functional Specification

47

The assessment defined the task and associated hazards and the required

system performance that is required.

The function specification will determine the required safety functions, their

design requirements and the type of functionality that is needed for each

mode of operation for each person that interacts with the machine.


Next Step Define Our Safety Functions

When Door Opens in zone #1,

tray packing stops, zone #2, tray

forming continues.

Safety Function:

Safety related stop function

initiated by a safe guard

Stopping hazardous

movement

Triggering Event:

Opening of guard door

Zone #1 Zone #2

Follow This Process for Every Safety Function in Every Machine Mode!


Step 3: Develop a safety project utilizing Safety Automation Builder.

49

This screen shot shows the layout drawing with identified hazard locations and access points that need to be protected!


Users can now start the safety selection process by selecting

input, logic and output devices for each identified safety need!

50

This screen shot shows the layout drawings with the selected safety devices!


Users can verify their design by exporting the SAB file to

SISTEMA for design verification! This is a sample report.

51

This screen shot shows the safety design verification report from SISTEMA!


Completed Bill of Material from ProposalWorks &SAB!

52

This screen shot shows the completed bill of material for the labeler machine safety system!


Now we have a price! We need to justify the investment!

53

We will use the Safety Return on Investment Tool to justify the project

based on projected reductions of injuries and productivity enhancements!

Let’s calculate our savings and ROI for this machine example!


The next step after selection, design verification & justification is design!

54

Now we need to start making schematics, developing programs and

configuration documents. We will guide you to locations that can help!

The Safety Functions documents are found on the safety resource center!


An additional tool that can help is Safety Accelerator Toolkit

55

Safety Accelerator Toolkit

The Safety Accelerator Toolkit can be found on the safety resource center or by asking your local Rockwell distributor!


An additional tool that can help is Connected

Component Building Blocks for Safety

56

The Safety Building Blocks can be found by asking your local Rockwell distributor for a CD!


Agenda

57

Closing & Wrap-up






Rockwell Automation the global leader in safety (Services/Products/Solutions)!

Best in class assessment services to help you to determine

safety system needs!

Safety Design Tools and resources to help engineers and

designers with safety system development.

Products selection and design verification tools to helps

engineers select product quickly and accurately.

Installation and start-up services to help meet productivity and

start-up needs.

Validation services to ensure that the safety system operates

as designed and constructed.

Preventive maintenance development services to ensure the

safety system continues to operate properly.

T63 - Safety System Development Process and … · Basic Safety Assessment or ... Awareness Means,...

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