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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
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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?
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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.
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 6
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?
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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.
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
8
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.
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
OHSA/US Standards Hierarchy
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
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
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
EN/ISO and OHSA/ANSI Standards Hierarchy Comparison
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
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
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 13
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?
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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.
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Evolution of Safety Systems
15 Copyright © Rockwell Automation, Inc. All rights reserved.
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
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Safety Standards of Today
16
Withdrawn
EN 954
CATEGORY
FAULT TOLERANCE
DIAGNOSTICS
2005/6 2011
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
State of the Art…
17
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.
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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!
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Merger of ISO 13849 and IEC 62061
What’s Next!
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Merger of ISO 13849 and IEC 62061
22
Where do we go from here?
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Merger of ISO 13849 and IEC 62061
23
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 24
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?
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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.
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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!
Copyright © 2009 Rockwell Automation, Inc. All rights reserved.
Category Performance Level
A performance Level is an improved Category!
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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)
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 33
a
b
c
d
e Per
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 PLr is achieved by… Balancing Structure (Cat), Reliability (MTTFd) and Diagnostic Coverage (DCavg)
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 34
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?
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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)
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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:
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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.
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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.
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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.
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 41
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?
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
We care what you think!
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PUBLIC INFORMATION
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PUBLIC INFORMATION
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