sf10 - what's your safety skill set?

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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

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Page 1: SF10 - What's Your Safety Skill Set?

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

PUBLIC INFORMATION

SF10 – What is Your Safety Skill Set

Page 2: SF10 - What's Your Safety Skill Set?

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

Page 3: SF10 - What's Your Safety Skill Set?

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

Page 4: SF10 - What's Your Safety Skill Set?

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

Page 5: SF10 - What's Your Safety Skill Set?

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?

Page 6: SF10 - What's Your Safety Skill Set?

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

Relationship of OSHA Standards

Page 7: SF10 - What's Your Safety Skill Set?

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

Page 8: SF10 - What's Your Safety Skill Set?

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

Page 9: SF10 - What's Your Safety Skill Set?

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

EN/ISO and OSHA/ANSI Standards Hierarchy Comparison

Page 10: SF10 - What's Your Safety Skill Set?

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

Agenda

Add Agenda Items Here

Add Agenda Items Here

Safety Life Cycle

OSHA and Standards Compliance

Why Implement Machinery Safety

Page 11: SF10 - What's Your Safety Skill Set?

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!

Page 12: SF10 - What's Your Safety Skill Set?

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:

Page 13: SF10 - What's Your Safety Skill Set?

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

Page 14: SF10 - What's Your Safety Skill Set?

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

Methodology and Risk Graph per RIA TR R15.306-2014

Page 15: SF10 - What's Your Safety Skill Set?

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

Page 16: SF10 - What's Your Safety Skill Set?

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

Page 17: SF10 - What's Your Safety Skill Set?

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!

Page 18: SF10 - What's Your Safety Skill Set?

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)

Page 19: SF10 - What's Your Safety Skill Set?

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

Safety Function Documents

Page 20: SF10 - What's Your Safety Skill Set?

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

Safety Functional Specification

Page 21: SF10 - What's Your Safety Skill Set?

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!

Page 22: SF10 - What's Your Safety Skill Set?

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?

Page 23: SF10 - What's Your Safety Skill Set?

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

Safety Automation Builder

Page 24: SF10 - What's Your Safety Skill Set?

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.

Page 25: SF10 - What's Your Safety Skill Set?

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)

Page 26: SF10 - What's Your Safety Skill Set?

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!

Page 27: SF10 - What's Your Safety Skill Set?

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.

Page 28: SF10 - What's Your Safety Skill Set?

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.

Page 29: SF10 - What's Your Safety Skill Set?

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

Validation Checklist (V&V Plan)

Page 30: SF10 - What's Your Safety Skill Set?

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!

Page 31: SF10 - What's Your Safety Skill Set?

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

Page 32: SF10 - What's Your Safety Skill Set?

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

Page 33: SF10 - What's Your Safety Skill Set?

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

Page 34: SF10 - What's Your Safety Skill Set?

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

TÜV Rheinland ; Technicians Course

Page 35: SF10 - What's Your Safety Skill Set?

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

TÜV Rheinland ; Functional Safety for Machinery

Introduction

Page 36: SF10 - What's Your Safety Skill Set?

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

TÜV Rheinland ; Functional Safety for Machinery

Engineer Certification

Page 37: SF10 - What's Your Safety Skill Set?

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

Safety Portal

http://marketing.rockwellautomation.com/safety-solutions/en/

Page 38: SF10 - What's Your Safety Skill Set?

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

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Page 39: SF10 - What's Your Safety Skill Set?

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