machine safety symposium - mcnaughton-mckay · - project: refers to machine or summary of safety...
TRANSCRIPT
![Page 1: Machine Safety Symposium - McNaughton-McKay · - Project: Refers to machine or summary of safety functions - Safety Function: Safety oriented response to an triggering event-Subsystem:](https://reader035.vdocuments.net/reader035/viewer/2022071111/5fe6eb3beb07c56773206944/html5/thumbnails/1.jpg)
Copyright © 2016 Rockwell Automation, Inc. All rights reserved.
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Machine Safety
Symposium
Software Tools
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Copyright © 2016 Rockwell Automation, Inc. All rights reserved.
EN954 ISO 13849-1Implications of Changing Standards…
• Move towards global safety standards
–EN-954 (Safety Categories) officially withdrawn on January 1, 2012
–EN ISO 13849-1 (Performance Levels) in effect since then
• ISO 13849-1 Specifies circuit performance in terms of
performance levels (PL)–Structure…. Category
–Reliability…. MTTFd
–Monitoring… DC avg
• Risk Assessment criteria are defined and mapped to Required
performance Levels (PLr)–Based on severity, frequency & avoidance
•Risk Assessments evaluate the potential hazards in order to
determine the required performance level.
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Two Sides of Functional Safety
Risk Assessment Model & Confirm PLr
Determines (PLr) Confirms PLr Achieved
Sistema Supports Both Sides of Analysis& Provides Critical Documentation
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Risk Assessment…A Foundation of Good Engineering Practice
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Machine Characteristics/Limits
Hazard Identification
Risk Estimation
Risk Reduction
Risk Evaluation
OKToo
High
Risk
Tolerable
Next
Hazard
Risk Analysis
Risk Evaluation/Reduction
-Repeatable-Team Based-Task Hazard Oriented-Analyzes
Severity, Frequency, Avoidance-Determines Appropriate PLr
-Mitigation Hierarchy-Solution Based OnStructure, Reliability,
& Monitoring-Confirms PLr is Achieved
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Risk Estimation
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ISO 13849 Risk Estimation… Severity
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ISO 13849 Risk Estimation… Frequency
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ISO 13849 Risk Estimation… Avoidance
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PLr
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Hierarchy of Risk Reduction Measures
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Achieving PLr
• System Structure…. Category
• Component Reliability….MTTFd
• Monitoring Capability…. Diagnostic Coverage
• Common Cause Failure Analysis… CCF
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Achieving PLr With ISO13849 Flexibility
• System Structure…. Category
• Component Reliability….MTTFd
• Monitoring Capability…. Diagnostic Coverage
• Common Cause Failure Analysis… CCF
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Functional Safety Roadmap
1. Determine the Required Performance Level
Perform Risk Assessment considering all hazards
2. Decide on the Architecture/Category
Cat B, 1, 2, 3, 4
3. Collect Data
From vendor documentation or libraries
4. Do the PL Calculation
Manually or leverage software tools
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Types of Categories (Structure)
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CAT B/1 CAT 2
CAT 3 CAT 4 (higher diagnostic coverage that CAT 3)
13849
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Functional Safety Roadmap
1. Determine the Required Performance Level
Perform Risk Assessment considering all hazards
2. Decide on the Architecture/Category… Cat B, 1, 2, 3, 4
3. Collect Data… MTTFd… From vendor documentation or libraries
4. Diagnostic Coverage and PL Verification
MTTFd Mean Time to Dangerous Failure
Low 0 -10 Years
Medium 10-30 Years
High 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%
Utilize SISTEMA Software… www.machinesafetysolutions.com
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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%
Performance Level PLr
Structure (Category)
Diagnostic Coverage (DC)
Reliability (MTTF)
Balancing Structure (Cat), Reliability (MTTFd) and Diagnostic Coverage (Dcavg)
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Copyright © 2016 Rockwell Automation, Inc. All rights reserved.
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Introduction to
SISTEMA & Safety
Automation Builder
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Copyright © 2011
Rockwell Automation, Inc.
17 17
Leverage SISTEMA for Real Time Validation
• SISTEMA – Safety Integrity Software Tool for the Evaluation
of Machine Applications
– SISTEMA provides a comprehensive method for evaluating ISO
13849-1 compliant Safety Control Circuits
– The tool enables you to model the structure of the safety-related control
components based upon the designated architectures.
– The tool offers automated calculation of a safety function’s attained PL
by using product data provided by safety product manufacturer.
– SISTEMA is a free software tool designed by Germany’s IFA (Institute
for Occupational Safety & Health).
SISTEMA simplifies the PL calculation of a safety function
Discover.RockwellAutomation.com
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SISTEMA TerminologyRelationship of 7 Hierarchical Levels in Sistema
INPUT LOGIC OUTPUT
- Project: Refers to machine or summary of safety functions
- Safety Function: Safety oriented response to an triggering event
-Subsystem: Group of Blocks within a defined structureInput - Logic - Output
-Channel: Connection of Blocks in series
-Test Channel: Confirms safety function channel is executing properly
-Block: Component in the function or test channel
-Element: Component reliability measure expressed as B10d value by vendor.Number of cycles until 10% of sample fail dangerously
“Safe operating stop
when a guard door
is opened”
Channel 1
Channel 2
Logic
Device
Safety Output
Contactor 1
Safety Output
Contactor 1
Switch channel 1
Switch channel 2
contactslinkage
contactslinkage
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Sistema Project View
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SISTEMA RA Library View
Product Data
Library
Selection
Rockwell
Automation
Product Library
SISTEMA User Interface – Library View
Attribute Tabs
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Sistema Report View
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Copyright © 2009 Rockwell Automation, Inc. All rights reserved.
Review the SISTEMA project
information to ensure that the
components, structure and design
meet the required Performance Level
SISTEMA Data created & exported
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SISTEMA… TUV Recommended
SISTEMA is the ONLY software tool recommended by TÜV!
– From TÜV Webinar in March 2009:
- Frank West
Senior Product Safety Service Engineer,
TÜV SUD
“We recommend [SISTEMA]. The important thing
to us as a third party assessor is that [SISTEMA] is
from a German governmental agency, so it’s not
attached to any particular vendor of components…
its neutrality is more reliable.
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Free Software Download
‘Safety Solutions’
To Access the
Safety Portal
www.machinesafetysolutions.com
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Safety Automation Builder
No-charge Software tool to help design a Machine Safety System
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Name, description, etc. here
Create a Project
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Choose or Import Graphics
Machine Images
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Answer Risk Assessment Question
Answer Safety Function Question
Answer Required PL Question
Select the default PL for the system
Risk Assessment Questions
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Click the zone shape and drag it onto the image
Re-size & rotate
as needed
Define Functional / Safety Zones
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Click the hazard tab to create a hazard
Click the type of hazard then select
& drag the icon onto the image then
re-size as needed
Define Functional / Safety Zones
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Input selection box for choose a
product type
Click on the configure box to start
Raise
Select & Configure Devices
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Copyright © Rockwell Automation, Inc. All rights reserved.32
Free Software Download
‘Safety Solutions’
To Access the
Safety Portal
www.machinesafetysolutions.com
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Introducing…Common Safety Functions Library
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• Examples for “safety relay” and “safety PLC” systems
• Breadth of examples including
• E-stop
• Light Curtains (Muting & Non-muting)
• Two hand control
• Enabling Switch
• Guard-locking switches
• Door interlocks
• Thorough documentation, wiring, programming, analysis, and more
Introducing…Common Safety Functions Library
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Machine Safety Symposium
http://www.machinesafetysolutions.com
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