an introduction to machinery safety essentials · machinery specific standards bs en iso 12100:2010...

2015 © TÜV SÜD Product Service Slide 128/06/2017

An Introduction to

Machinery Safety

Essentials

Presented by Lee Ray

[email protected]

Who am I?

Name Lee Ray

Title Key Accounts Manager

Employer TÜV SÜD Product Service

Experience Almost seven years in the field of Machinery Safety Compliance

History Apprentice Trained Multi Skilled Engineer. Graduate Member of IOSH. Started with

Laidler Associates in Sept 2010 which was taken over by TÜV SÜD Product Service.

Left for a short period to take a position with Siemens Metal Technologies as Product

Safety Coordinator.

Telephone 07584 488771

E-mail: [email protected]

TÜV SÜD Product Service Slide 225/04/2017 CE Marking and Electrical Safety Workshop

Facilities:

Training Room.

Teas / Coffees.

Lunch.

Emergency Measures.

Toilets.

Mobile Phones.

Information

Machinery Safety Essentials

TÜV SÜD Product Service Slide 4CE Marking and Electrical Safety Workshop25/04/2017

By the end of this Workshop the

participants will:

• Have a understanding of the

Machinery Directive requirements.

• Understand the requirement to

PUWER assess equipment.

• Know the requirements for Safety

Related Control Systems &

Functional Safety

An Introduction to Machinery Safety Essentials

1Machinery Directive – legal

requirements and responsibilities

2 Understanding PUWER

3 Functional Safety


Responsibilities

The Manufacturer The User

TÜV SÜD Product Service Slide 617-06-28 CE Marking and PUWER Assessment25/04/2017TÜV SÜD Product Service Slide 6CE Marking and Electrical Safety Workshop

Single European Market


• 28 different countries

• 28 different legal systems

• All countries introduce the same laws into their own legal systems

• The Directives are adopted as Laws and must be complied with before supplying equipment into the European Economic Area (EEA).

Directives that could apply to machinery


• The Machinery Directive

2006/42/EC.

• The Low Voltage Directive

2014/35/EU.

• The EMC Directive 2014/30/EU.

• The Pressure Equipment Directive

2014/68/EU.

• Equipment for Explosive Atmosphere

2014/34/EU.

Why do we have to comply?


Because all of the European directives

are brought into UK law by the issue of

Regulations, it makes it a criminal

offence, punishable by fines and

imprisonment, not to comply.

Why do we have to comply?


Machinery Directive – Supply of

Machinery Regulations

Low Voltage Directive – Electrical

Equipment (Safety) Regulations

EMC Directive – EMC Regulations

PED – Pressure Equipment Regulations

ATEX - Equipment and Protective

Systems Intended for Use in Potentially

Explosive Atmospheres Regulations

Definitions of Machinery


• An assembly fitted with or intended to be fitted with a drive system other than directly applied manual or animal effort, consisting of linked parts or components, at least one of which moves, and which are joined together for a specific application.

• Lifting apparatus whose only power source is directly applied manual effort.



• An assembly of machines and/or

partly completed machinery which, in

order to achieve the same end are

arranged and controlled to function

as an integral whole.



• Interchangeable equipment is a device which, after placing into service of machinery or tractor is assembled with that machinery or tractor by the operator himself in order to change its function.

Definition of a Safety Component (Article 2(c))


• which serves to fulfil a safety function,

• which is independently placed on the market,

• the failure and/or malfunction of which endangers the safety of persons and,

• which is not necessary in order for the machinery to function, or for which normal

components may be substituted in order for the machinery to function.

An indicative list can be found in Annex V.

TÜV SÜD Product Service Slide 1517-06-28

Examples of Safety Components

CE Marking and Electrical Safety Workshop25/04/2017TÜV SÜD Product Service Slide 15

Scenarios where the MD applies


• If you are creating an assembly of machines by interlinking a

series of existing machines you are in effect creating something new.

• Therefore who ever is carrying out the work must ensure that the whole

assembly complies with the Directive.

• Regardless of the age of the machines.

• If you are altering the function or performance of a machine or an assembly of

machines you are again creating something new and must ensure that the

Directive is complied with.

Scenarios where the MD applies


These requirements also apply to in-house machinery.

• where the manufacturer of relevant machinery himself puts that machinery into service.

• Having directly imported machinery from a country or territory outside the EEA and puts that machinery into service.

The Four Steps to Compliance for the Machinery Directive


1. Complying with the EHSR’s in Annex I

2. Compiling the Technical Construction File (TCF) in accordance with Annex VII

3. Raising the Declaration of Conformity in accordance with Annex II

4. Affixing the CE Mark in accordance with Annex III

1. General. 2. Foodstuffs, Medical.

3. Mobile Machinery. 4. Lifting Equipment.

5. Underground Machinery. 6. Lifting or Moving of Persons.

How to Comply – EHSR’s


Step 1

• The Essential Health and Safety Requirement’s laid down in the Machinery

Directive are mandatory.

• They are separated into six sections:

EN Standards


Use of Standards

There are Three Types of Standard:

• “A” type apply to all machines.

• “B” type are designed to promote safety and split in to B1 and B2.

• “C” type apply to a specific type of machine.

TYPE C

MACHINERY

SPECIFIC

STANDARDS

BS EN ISO 12100:2010

Safety of machinery Basic concepts, general

principles for design. Risk Assessment and

risk reduction

BS EN 13849-1Safety-related parts of

control systems.

PR EN 418

Emergency Stop

SPECIFIC PROTECTIVE

DEVICE STANDARDS

2 Hand Controls

Light Curtains

Safety Switches etc

BS EN 60204 - 1

Electrical

Equipment

BS EN ISO 13850

Emergency Stop

EN Standards


EN Standards


Why we apply Standards

The standards are used to apply “good engineering practice” and

“state of the art” which in turn allows a presumption of conformity to

be assumed.

We apply the relevant standards which are quite prescriptive on what

measures should be in place to achieve compliance.

EN Standards


Examples of “B” Type Standards

• BS EN ISO 14120 Relates to the selection and manufacturing of Guards.

• BS EN 349 Relates to minimum gaps to prevent Crushing of the whole body

• BS EN ISO 13857 Relates to the positioning of guards to protect the upper limbs

and the lower limbs.

BS EN ISO 13857


Enclosing Fixed Guard


Suitability of Guards


Examples of C Type Standards

• BS EN 415

Series “Safety of Packaging Machines” in 10 parts, part 4 applies to Palletisers

and De-Palletisers.

• BS EN 10218-1

“Industrial Robots Recommendations for Safety”.

• BS EN 12417

“Safety of Machine tools Machining Centres”.

EN Standards


Technical File

CE Marking and Electrical Safety Workshop

Step 2

A Technical Construction File (TCF) including:

• a general description of the machinery,

• the overall drawing of the machinery and drawings of the control circuits, as well as the pertinent descriptions and explanations necessary for understanding the operation of the machinery,

• full detailed drawings, accompanied by any calculation notes, test results, certificates, etc. required to check the conformity of the machinery with the essential health and safety requirements,

TÜV SÜD Product Service Slide 2917-06-2825/04/2017TÜV SÜD Product Service Slide 29

Overall drawing


Technical File

Detailed Drawings


Technical File

Circuit Diagram


Technical File

Technical File


A list of the essential health and safety requirements which apply to the machinery,

means explaining how the machine complies with the requirements.

This can be in the form of:

• Risk assessments where the requirement has not been achieved and what

control is required to be implemented for compliance

• A report showing what harmonised standards and technical documents have

been applied

• Justification where deviation occurs from the standards to demonstrate the

machine is still compliant

• Test reports as required in the EHSR’s


Technical File


EHSR Checklist

Technical File


• A copy of the instructions for the machinery,

• Where appropriate, the EC declaration of incorporation for included partly

completed machinery and the relevant assembly instructions for such machinery,

• Where appropriate, copies of the EC declaration of conformity of machinery or

other products incorporated into the machinery,


Technical File


• A copy of the EC declaration of conformity;

• For series manufacture, the internal measures that will be implemented to

ensure that the machinery remains in conformity with the provisions of the

Directive. (Quality System).


Declarations


Step 3

• Declaration of Conformity or

Incorporation.

• This has to accompany the machine.

Step 3

• The Declaration of Incorporation is used

with a machine which is specifically

designed to be incorporated into an

assembly of machines and not capable of

independent work.

Declarations


Changes to Declaration of Conformity


Step 4

• Name and address of the person who is authorised to compile the Technical File,who must be established in the European Community.

• Where appropriate a statement confirming declaration of conformity with other applicable directives.

• The place and date of the declaration.

• Must be typewritten or handwritten in capital letters.

It is illegal to affix the CE mark to a machine unlessit complies with all applicable Directives.





3 Functional Safety



Implementing the Work Equipment Directive

2009/104/EC.

Provision and Use of Work Equipment Regulations 1998

PUWER 98

• Made under the Health & Safety at Work Act 1974.

• Only applies where the HSWA applies.

• Does not require a CE mark, Technical File or Declaration of Conformity.

• Mobile work equipment.

• Lifting equipment.

• The inspection of work equipment.

APPLIES TO ALL WORK EQUIPMENT, REGARDLESS OF AGE INCLUDING CE MARKED EQUIPMENT

PUWER ‘98

• It could result in prosecution and penalties, on conviction,

of a fine of up to:

a) On summary conviction £20,000 fine and or 3 Months in prison.

b) On conviction on indictment unlimited fine and or two years imprisonment

c) Many more prosecutions under PUWER than other Regulations

If You Don’t Comply

• Part I Introduction.

• Part II General. Regs 1 to 24

• Part III Mobile Work Equipment. Regs 25 to 30

• Part IV Power Presses. Regs 31 to 35

• Part V Miscellaneous. Regs 36 to 39

• Regulations 1 to 9 with the exception of regulation 6 are to do with Policies and

Procedures and look at Policies and Procedures, Maintenance, Operating

Information, Training, Health and Safety Policies, etc.

Layout of PUWER ‘98

Where the safety of work equipment depends on installation it must be inspected:

(a) After installation and before being put into service for the first time or

(b) After assembly at a new site or in a new location.

Work Equipment exposed to conditions causing deterioration liable to result in a

dangerous situation must be inspected

Regulation 6 part 1 - Inspection

• At suitable intervals, and

• Each time circumstances liable to jeopardise the safety have occurred.

• The results of any inspection made under this regulation must be recorded.

• These records must be kept until the next inspection is recorded.

If you sell or purchase a second hand machine, it must also be inspected.

Regulation 6 part 2&3 - Inspection


Regulation 6 - Inspection

• The persons who determine the nature of the inspections

required and who carry out the inspections are competent to do so.

• The competent person deciding the nature of the inspection should have the

necessary knowledge and experience to decide what the inspection should

include, how and when it should be carried out.

• The competent person carrying out the inspection should have the necessary

knowledge and experience to know what to look at, what to look for, how and who

to report to.

• Covers things like Testing of Light Guards and Scanners etc.

Regulation 6 - Inspection

Requires that an Employer must ensure that any equipment that is subject

to European Directives complies with the Directives that apply to it.

• Relevant Declarations or Certificates provided

• Instructions to allow for safe use

• Information on residual risks (noise, vibration etc.)

• Any obvious signs of non-compliance

Regulation 10 – Community Requirements

• Regulation 11 – Access to Dangerous Parts of Machinery

• Regulation 12 – Specified Hazards, Fire, Heat etc

• Regulation 13 – High/Low Temperatures

• Regulation 14 – Start Controls

• Regulation 15 – Stop Controls

• Regulation 16 – Emergency Stop Controls

Regulations 11-24

• Regulation 17 – Operating Controls

• Regulation 18 – Control Systems

• Regulation 19 – Isolation of Energy

• Regulation 20 – Stability

• Regulation 21 – Lighting

• Regulation 22 – Maintenance

• Regulation 23 – Markings

• Regulation 24 – Warnings

Regulations 11-24

• Regulation 25 - 30 – Mobile Work Equipment

• Other Regulations on Power Presses etc

• Revocation of Other Regulations

Regulations 25 - 39

Life Cycle of a Machine

PUWER Danger Area

CE MARKING

TÜV SÜD Product Service Slide 53Machinery Safety Version 2.0 2017

Changing a machine in a assembly of machines or component in a

single machine.

If the function or performance are not altered this is classed as a repair and

no action other than a risk assessment and compliance with PUWER 98 is

required.

Changing a machine/ component

Machinery Safety Version 2.0 2017TÜV SÜD Product Service Slide 54





3 Functional Safety


References

Functional Safety of Machinery: EN ISO 13849-1 Slide 56

Standards for Functional Safety

Two standards are available for use in the machinery

sector

Source: BGIA Report 2/2008e


• EN 62061

– Safety of Machinery: Functional safety of electrical, electronic and programmable

electronic control systems

– Technology specific

– Covers all levels of complexity

• EN ISO 13849-1

– Safety of machinery — Safety-related parts of control systems Part 1: General

principles for design

– Is a replacement for EN 954-1

– Not technology specific, can be used for any energy source.

– Can also be used for Programmable Systems (Safety PLC’s)

Which standard to use?


EN ISO 13849-1

Source: BGIA Report 2/2008e


Frequency of Failures

Out of control

Why control systems go wrong and how to

prevent failure?

(Out of control, 2nd edition 2003, Health & Safety Executive HSE – UK)


• Failure related in a deterministic way to a certain cause, which can only be

eliminated by a modification of the design or of the manufacturing process,

operational procedures, documentation or other relevant factors– the safety requirements specification,

– the design, manufacture, installation, operation of the hardware, and

– the design, implementation, etc., of the software.

• Further information can be found in EN ISO 13849-1, in particular in Annex G

Systematic failure


Overall Risk Estimation/Risk Reduction

EN ISO 13849-1 Figure 1


Risk estimation – general principles

Risk related

to the

identified

hazard

Severity

of the

possible

harm

(Se)

Probability of occurence of that harm

Frequency and duration of exposure (Fr)

Probability of occurrence of

a hazardous event (Pr)

Probability of avoiding or

limiting harm (Av)

=and


• A control system in a machine should be regarded as being safety-related if

it contributes to reducing any risk to an acceptable level or if it is required to

function correctly to maintain or achieve safety.

Safety-Related Controls

What is a Safety Related Control System?


EN ISO 13849-1

• 4.2.2 – For each safety function the characteristics and the required performance

level shall be specified

• 4.3 Determination of required performance level (PLr)

– For each selected safety function to be carried out by a SRP/CS, a required

performance level (PLr) shall be determined and documented (see Annex A for

guidance on determining PLr).

Specifying requirements


• Safety related stop function initiated by safeguard

• Local control function

• Hold to run

• Enabling device

• Muting function

• Prevention of unexpected start up

• Control modes and mode selection

• Emergency stop

Safety Functions - Examples


EN ISO 13849-1 Annex A risk graph


• Severity of Injury.– S1 Slight injury, (bruise).

– S2 Severe injury, (Amputation or death).

• Frequency of exposure to injury.– F1 Seldom.

– F2 Frequent to continuous ( Frequent to continuous are not defined in the

standard).

• Possibility of avoiding the hazard.– P1 Possible.

– P2 Less possible. Based on the speed of approach of the hazard and the ability of the operator to avoid

the hazard. If the operator can avoid the hazard then you would choose P1.

Risk Graph Parameters


• The Performance Level achieved by a Safety Function depends on:

– The architectures of the SRP/CS Categories

– The reliability of components E.g. Mean Time To Dangerous Failure (MTTFd)

– The effectiveness of error detection Diagnostic Coverage (DC)

Factors to establish PL


Designated Architectures - Categories

B SRP/CS shall be designed in accordance with relevant standards

1 SRP/CS shall use well tried components and principles. No protection against

faults.

2 SRP/CS shall use well tried principles and functions shall be “checked at

suitable intervals”. Testing rate better than 100 times demand rate. No

protection against faults.

3 SRP/CS shall be designed, so that: a single fault in any of these parts does

not lead to the loss of the safety function; and whenever reasonably

practicable the single fault is detected.

4 SRP/CS shall be designed, so that: a single fault in any of these parts does

not lead to a loss of the safety function; and the single fault is detected at or

before the next demand upon the safety function. If this is not possible, then

an accumulation of faults shall not lead to a loss of the safety function



Cat B & 1

Cat 2

Cat 3

Cat 4

Designated Architectures - Categories

Cat 3

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