functional safety and the changing compliance landscape

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

PUBLIC INFORMATION

Functional Safety and the Changing Compliance Landscape

Chris Brogli

Global Business Development Manager for Safety


Session Purpose and Intent

This session is meant to provide insight to functional

safety, compliance and the global trends in safety.

Additional sessions (SF01, SF02, SF03, SF04 & SF05)

provide additional safety content.

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 3

Agenda

Closing & Wrap-up

How can you ensure that you are in compliance?

Trends in Safety

OSHA Requirements

History of Safety

What is functional safety?


History of Safety in USA

4

1877 – Massachusetts, required guarding of belts, shafts and gears

1890 – Nine US states required machine guarding

1930 – All US states had established job-related safety laws

1934 – Bureau of Labor Standards (F. D. Roosevelt - Frances Perkins)

Promote safety and health for working men and women

1970 – Occupational Safety and Health Act (William Steiger’s Act)

1981 – Lost Workday Incident Rates policy established by OSHA

1991 – EN 292 – Basic Concepts of Machine Safety

1996 – EN 954 and EN 1050 – Machinery Safety

Safety has been a growing part of the human integrated manufacturing environment. Our responsibility is required.


U.S. Legislation

1970 Williams Steiger Occupational Safety and Health Act

Purpose: The Congress declares it to be its purpose and policy ... to assure so far as possible every working man and woman in the Nation safe and healthful working conditions and to preserve our human resources.

Check out their website on www.osha.gov


Agenda

Closing & Wrap-up


Trends in Safety

OSHA Requirements

History of Safety



Employer Requirements Defined by OSHA

OSHA requires that each employer shall furnish to each of his

employees employment and a place of employment which are free from

recognized hazards that are causing or are likely to cause death or

serious physical harm to his employees.

OSHA specifies minimal standards, and offers little, if any, assistance in

compliance solutions.

OSHA uses industry standards as well as manufacturer’s instructions

when investigating accidents.

Manufacturers and employers should apply consensus standards to help

assure safety.


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Standards Organizations

Initials Sponsoring Organization Scope

ANSI American National Standards Institute U.S.A.

AS Australia Standard Australia

ASME American Society of Mechanical Engineers U.S.A.

ASSE American Society of Safety Engineers U.S.A.

B11 Association of Manufacturing Technology U.S.A.

CSA Canadian Standards Association Canada

EN European Norm European

Community

IEC International Electrotechnical Commission Global

ISO International Organization for Standardization Global

NFPA National Fire Protection Association U.S.A.

OSHA Occupational and Safety Health Administration U.S.A.

PMMI Packaging Machinery Manufacturer’s Association U.S.A.

RIA Robotic Industries Association U.S.A.


OHSA/US Standards Hierarchy

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OHSA Machine Safety 1910.xxx

Machine Safety - General Safety

Requirements ANSI B11.GSR

Machine Safety - Principles for Risk

Assessment ANSI B11.TR3

Machine Safety - Selection of Programmable Electronic Systems

(PES/PLC) for Machine Tools ANSI B11.TR4

Electrical equipment of machines

ANSI/NFPA 79


EN/ISO Machinery Directive Standards Hierarchy

European Machine Directive 2006/42/EC

Machine Safety - Basic concepts

EN/ISO 12100

Machine Safety - Principles for Risk Assessment

EN/ISO 14121

Machine Safety - safety-related parts of control systems EN/ISO 13849-1

Non-electrical and simple electrical

Machine Safety - Electrical equipment of

machines IEC 60204-1

Machine Safety - Functional safety of

EEPES control systems

IEC 62061


EN/ISO and OHSA/ANSI Standards Hierarchy Comparison


OHSA Machine Safety 1910.xxx

Machine Safety - General Safety

Requirements ANSI B11.GSR

Machine Safety - Principles for Risk

Assessment ANSI B11.TR3

Machine Safety - Selection of Programmable Electronic Systems

(PES/PLC) for Machine Tools ANSI B11.TR4

Electrical equipment of machines

ANSI/NFPA 79

European Machine Directive 2006/42/EC

Machine Safety - Basic concepts

EN/ISO 12100

Machine Safety - Principles for Risk Assessment

EN/ISO 14121

Machine Safety - safety-related parts of control systems

ISO 13849-1 Non-electrical and simple electrical

Machine Safety - Electrical equipment of

machines IEC 60204-1

Machine Safety - Functional safety of

EEPES control systems

IEC 62061


What does this mean to us? What are the steps?

Step 1 - Define the Requirements

Step 2 – Follow and Assessment Process

Step 3 – Utilize a defined Assessment Tool/Method

Step 5 – Follow the proper regional

electrical installation standard.

The European & North American machinery directives/standards outlines the general requirements that shall be followed to ensure that machines are assessed and that proper protection methods have been implemented to ensure personnel protection.

These harmonized standards (EN/ISO/ANSI) outline the requirements for assessments.

The ISO and IEC standards both address the design of the safety related parts of the control system including the requirements of design verification.

IEC/NEC/NFPA standard s address electrical installation and wiring practices.

Step 4 - Determine the design method and verify the design


Agenda

Closing & Wrap-up


Trends in Safety

OSHA Requirements

History of Safety



Trends in Safety

In recent years there has been a move towards globalizing safety standards. This has resulted in a re-write of many of the EN and ISO standards. Many of the changes were to take place in December of 2009 but were extended two years to December 2011.

These changes include a systems approach to safety. This systems approach looks at the equipment, the raw materials, the finished products, the people that interact with the system and the environment the equipment is operated in order to determine the system’s required performance level (PLr).

Performance levels are determined through the use of risk assessments.

Employers and equipment manufacturers are encouraged to use risk assessments to determine the potential hazards associated with operating a machine or system in order to determine the required performance level.


Evolution of Safety Systems

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1960 1970 2000 Future 1980 1990

You invest a safety system to protect people. You invest in advanced safety technology to enhance machine performance.

2010

Legacy • High Productivity

• Low Safety

• No Assessment

Initial Safety • Lower Productivity

• Medium to High Safety

• Hazard Assessment

Modern Safety • High Productivity

• High Safety

• Risk Assessment


Safety Standards of Today

16

Withdrawn

EN 954

CATEGORY

FAULT TOLERANCE

DIAGNOSTICS

2005/6 2011


State of the Art…

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Does the standard address critical technologies that exist today and how

to apply those technologies in a safety-related way?

EN 954? – A standard that was developed for electro-mechanical

type systems (Relays/Contactors/Etc.)

ISO 13849-1? A standard that was developed for more advanced

solid-state type products (Safety PLC’s/Controllers/Drives/Servo’s)

ANSI RIA 15.06? An evolving standard that is moving from the EN954

type methodology toward new technologies that are addressed by

ISO13849, IEC62061 and IEC61508.


Safety Standards of Today

18

EN954 Withdrawn EN 954

CATEGORY

FAULT TOLERANCE

DIAGNOSTICS

2005/6 2011

FAULT TOLERANCE

DIAGNOSTICS SRS

RELIABILITY

SYSTEMATIC

FSM IEC/EN 62061 SIL

EN ISO 13849 PL


ISO-13849 and ANSI

19

ANSI/RIA-15.06 has changed!

ANSI/RIA now references ISO-10218 & ISO13849. (This just happened)

Documentation is being developed and will release in June of this year!

This means that Performance Levels are here to stay!


Merger of ISO 13849 and IEC 62061

What’s Next!


Safety Future? Merger of ISO 13849 and IEC 62061

21

Withdrawn

FAULT TOLERANCE

DIAGNOSTICS SRS

RELIABILITY

SYSTEMATIC

FSM IEC/EN 62061 SIL

EN ISO 13849 PL

EN 954

CATEGORY

FAULT TOLERANCE

DIAGNOSTICS

2005/6 2011 2016 ?

IEC ISO 17305



22

Where do we go from here?



23


Agenda

Closing & Wrap-up


Trends in Safety

OSHA Requirements

History of Safety



IEC 61508 - Functional Safety PL & SIL

IEC/EN 61508

Functional safety of electrical, electronic, and programmable electronic

safety-related systems (EEPE/CS)

IEC/EN 61511

SIS

(SIL1 – SIL4)

IEC/EN 62061

EEPE/CS

(SIL1 - SIL3)

EN/ISO 13849

SRP/CS

(PLa - PLe)

Process Machinery

Software


Changing to Functional Safety

ISO 13849-1 IEC 62061

Safety Categories are no longer in effect since EN954-1 was withdrawn in December of 2011.

ISO 13849-1 has replaced EN954-1 as the most commonly followed international machine safety standard.

ISO 13849-1 and IEC 62061 are known as functional safety standards. These standards look at how well a safety system needs to operate. This allows us to use new technologies to drive productivity and safety. These new technologies are called contemporary safety solutions.


Compliance Productivity Performance

New Standards are helping by allowing new

technologies and solutions to be used!

Profits

Functional safety is a new term that is being used in the industry to look at how well the safety system needs to function. Manufacturing plants are seeing contemporary safety & control solutions as a method of enhancing productivity and machine utilization


Contemporary Safety Automation

In the past, safety and production control systems shared little, if any information

Harmonizing your safety and production control systems offer tremendous opportunities to improve productivity

Shared diagnostics on common HMI for faster troubleshooting

Safety system that changes parameters based on the state of the production system

Zone control to enable continued production flow when one zone is shut down

Better shut down and restart of production systems after a safety event

Operating Equipment

Control System

Safety System

A machine control strategy that includes both safety and production control systems

– Purpose of production system is to produce

– Purpose of safety system is to protect


ISO 13849-1 Explanation

ISO 13849-1 is the result of improvements to the old EN-954-1 standard. EN954 was developed for simple electro-mechanical devices. ISO13849 allows for the use of solid state devices!

ISO13849 introduces new design concepts that provide guidance on the design and integration of safety components to meet required performance levels (PLr).

Required Performance Levels (PLr) is determined by doing a risk assessment!


Category Performance Level

A performance Level is an improved Category!


Categories Still Exist but Only as a Subpart of ISO13849!

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Categories are still the Major Piece of the Puzzle!

Categories are also referred to as Structure!

31

CAT B/1 CAT 2

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


Structure + Reliability + Monitoring = Safe Systems

32

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%

Reliability and Monitoring Calculations


a

b

c

d

e Per

form

ance

Lev

el

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 PLr is achieved by… Balancing Structure (Cat), Reliability (MTTFd) and Diagnostic Coverage (DCavg)


Agenda

Closing & Wrap-up


Trends in Safety

OSHA Requirements

History of Safety



What Do the Standards Say About Machine Safety?

Companies have 2 choices when dealing with machine safety.

Choice 1 – Lock-out/Tag-out (Also known as Energy Isolation)

Choice 2 – Alternative means (Also known as Machinery Safety)


Energy Isolation vs. Machine Guarding

Machine Maintenance

Regulation: Lockout / Tagout or Energy Isolation

Requirement: Release stored energy

Tasks: Isolation of Mechanical / Electrical Equipment for Service and Maintenance

Production Operation

Regulation: Machine Guarding or alternative protection means

Requirement: Protect operators from machine production hazards

Tasks: Operator Interaction for Regular Machine Production

Minor servicing must be routine, repetitive and integral to the operation of the system.

Minor Servicing Exception • minor jams, minor tool changes & adjustments, exchange

Regulation: Machine Guarding or alternative protection means

• Requirement: Protect operators from machine production hazards when performing minor servicing

• Tasks: Minor servicing such as clearing of work piece, etc.

Minor Service Exception to Lockout Tagout

Must provide alternative Measures that offer effective protection


Lock-out/Tag-out or Energy Isolation Purpose

37

The purpose is to protect against the consequences of unexpected "energization" or start-up of mechanical systems, or the release of stored energy.

An employee is required to remove or bypass a guard or other safety device. Anytime an employee is required to place any part of his or her body into a hazardous area of a machine or piece of equipment where work is actually performed.

The standards say Lock-out Tag-out will be followed when:


Exceptions to Lock-out Tag-out or Energy Isolation

38

Note of Exception:

Minor tool changes and adjustments, and other minor servicing activities,

which take place during normal production operations, are not covered by

this standard if they are routine, repetitive, and integral to the use of the

equipment for production, provided that the work is performed using

alternative measures which provide effective protection.

“Alternative Measures” include machine safeguarding which

should be determined through the use of a risk assessment.


How Do You Apply Alternative Measures?

Machine hazards should be determined by the use of a safety or risk assessment.

The assessment will determine the required system performance that is required.

The assessment will also determine possible mitigation solutions.


What Standard Should You Use?

It depends on:

Regional requirements

National regulations

Industry type

Technologies being used

Where the machine or system will be utilized

Considerations

What type of technology is going to be utilized

Simple or Complex system needs

The ISO & IEC standards will get you where you need to be anywhere on the globe! ISO12100 is a recommended method or assessment and ISO13849, IEC62061 and IEC61508 are the recommended design standards.


Agenda

Closing & Wrap-up


Trends in Safety

OSHA Requirements

History of Safety



How Can Rockwell Automation Help?

Safety Consulting Services

Training

Conformity Audits

Hazard Assessments

Safety Assessments

Risk Assessments

Safety System Validation

Safety Implementation Services

Project Management & Turnkey Safety System Integration

Sales Resources

Safety Seminars

Product Selection Tools

Design Tools


We care what you think!

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functional safety and the changing compliance landscape

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