Pharm connect congress 2014
Budapest Feb. 26. – 27.
Thomas Schulz
Head of ISM and KAM Biotech/Pharma
Phone: +49-711/347-52192
Mail: [email protected]
Safety in pneumatic automation
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Safety in pneumatic automation
Presentation
1. General information about Festo
2. Legal Regulations - Specifics for Factory- and Process-Automation
3. Risk analysis - risk assessment - risk reduction
4. Safety Functions Categories (input logic output)
5. Applications
• Increased safety for double acting valves – defined safety position
• Increased safety for single acting valves – quick exhausting
• Combined safety measures by pressure zones and quick exhaust valves
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Festo – an independent family-owned company
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Some Facts & Figures
• Pneumatic & Electric Automation
Technology offering solutions for
Factory & Process Automation
• Learning Systems,
Training & Consulting
• Turnover 2,3 billion € (2013)
• 61 international Festo companies
• 300.000 Customers worldwide
• 30.000 Components
in countless variants
• 16.000 Employees worldwide
• Investments in % of turnover:
R&D: 7,0 %
Training: 1,5 %
Festo Technology Centre and
Headquarters , Esslingen, DE
Festo Customer Service Centre
and production plant, St. Ingbert, DE
Legal regulation – Risk assessment
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Laws e.g. EC Machinery Directive 2006/42/EC
Risk assessment
Risk analysis Risk assessment Risk reduction
Design measures
Technical measures
User information
Evaluation : PL ≥ PLr SIL ≥ SILr
Safe machines
Evaluation and
assessment of technical
safety measures
Standardized process
+
„check list “
Risk reduction
Evaluation whether
risk reduction is sufficient
Safety function Input Logic Output
Risk Analysis – Determininig the performance level
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S Severity of injury
S1 Slight /Normally reversible injury
S2 Serious (normally irreversible
injury, including death
F Frequency and/or duration of
exposure to the hazard
F1 Seldom to less often or brief
F2 Frequent to continuous and/or
long
P Possibility of avoiding the hazard
P1 Possible under specific conditions
F2 Scarcely ever possible
a – e Performance level PL
DIN EN ISO 13849-1 Appendix 1.2.3
a
b
c
d
e
Signalling structure - categories
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Category B and Category 1
Signal 1 channel
Failures will not be detected 0 fault safety
Category 1 uses only “prooven components“
Input Logic Output Input-
signal
Output-
signal
Signalling structure - categories
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Category 2
• Additional testing and monitoring failure detection possible
• 100x test of the function before the request by the machine control System
• No permanent fault monitoring 0 fault detection between the test phases
Input Logic Output Input signal Output signal
Test signal Monitoring
Logic Output
Monitoring Trigger signal
Second path for shut down
or indication
Signalling structure - categories
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Category 3
• Signals via 2 channels
• Some, but not all faults are detected before or during the next request
• 1 Fault safety multiple undetected faults lead to the loss of Safety function
Input Logic Output Input signal
Output signal
Test signal
Monitoring
Logic Output Input Output signal Input signal
Monitoring
Signalling structure - categories
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Category 4
• Signals via 2 channels
• Every fault must be detected before or during the next request
• 1 Fault safety
Input Logic Output Input signal
Output signal
Test signal
Monitoring
Logic Output Input Output signal Input signal
Monitoring
Signalling structure - categories
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Category B and Category 1 Category 3
Category 2 Category 4
Risk Assessment PL vs. SIL
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a
b
c
d
e
1
2
3
Cat. B Cat. 1 Cat. 2 Cat. 4 Cat. 3
MTTFd = Mean Time To Failure (dangerous) High Demand Mode
Probability of failure (per hour)
max. failure
Performance level PL Safety Integrity Level SIL
Applications - Plant and machine safety
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Machine directives and safety procedures request in many cases a safe shutdown of
machines and process equipment in case of an emergency. To increase plant safety
the following technical measures can be implemented:
1. Double acting valves (DA)
Bring the valve to a defined position with the right pneumatic functions
2. Single acting valves (NC or NO)
Quick exhausting of an emergency to prevent unintended actuation of a process
valve due to back pressure and pressure peaks in the system
3. Application: Filling station for powder
Combined safety measures by pressure zones on a valve terminal and quick
exhausting
Increased safety for double acting valves – defined safety position
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• Double acting valves or cylinders have no defined safety position. In case of a shutdown or emergency this might cause a problem.
• A defined safety position can be integrated pneumatically by either holding the pressure in the actuator or exhausting it.
Exhausting
Pressurizing
Increased safety for double acting drives – defined safety position
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Double acting cylinder <Safety operation> <Compressed air + voltage available>
1
Action : when applying compressed air, cylinder moves to safety
position
Increased safety for double acting drives – defined safety position
Double acting cylinder <Safety operation> <Compressed air + voltage applied>
Action : cylinder is forced into
safety position
2
Increased safety for double acting drives – defined safety position
19
Double acting cylinder <Safety Operation> <Supply voltage ON, Step 1>
Action : electromagnetic valve ON
(„Enable“)
3
Increased safety for double acting drives – defined safety position
20
Double acting cylinder <Safety Operation> <Supply voltage ON, Step 2>
Action : pneumatic valves ON
(„Enable“)
4
Increased safety for double acting drives – defined safety position
21
Double acting cylinder <Safety Operation> <Cylinder positioning>
Action : 5/3-valve „move right“
5
Increased safety for double acting drives – defined safety position
22
Double acting cylinder <Safety Operation> <Cylinder positioning>
Action : 5/3-valve „move left“
6
Increased safety for double acting drives – defined safety position
23
Action : supply voltage OFF
Double acting cylinder <Safety Operation> <Supply voltage failure, Step 1>
7
Increased safety for double acting drives – defined safety position
24
Action : electromagnetic valve OFF
Double acting cylinder <Safety Operation> <Supply voltage failure, Step 2>
8
Increased safety for double acting drives – defined safety position
25
Double acting cylinder <Safety Operation> <Supply voltage failure, Step 3>
Action : pneumatic valves OFF,
cylinder moves to safety position
9
Increased safety for double acting drives – defined safety position
26
Double acting cylinder <Safety Operation> <Supply voltage failure, Step 4>
Action : Cylinder is forced into
safety position
10
Increased safety for double acting drives – defined safety position
Increased safety for single acting valves – quick exhausting
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In case of an emergency single acting valves will fall back into their defined safety position. Normally the pneumatic system will remain under pressure. Accidently triggered pressure peaks might actuate a process valve possible risk
• Additional safety can be achieved by:
o Include a quick exhausting valve in the pneumatic system. In an emergency shut down the pneumatic system will be exhausted quickly.
o Include an integrated locking device for protection against unexpected start up
Increased safety for single acting valves – quick exhausting
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The highest safety for this application can be reached e.g. with MS-6-SV-E or MS-6-SV-E-ASIS
Cat. 4
PL e
Diagnostic coverage Integrated, internal sensing
of the piston position
Channels 2
Certificate IFA
Safety component to
MD 2006/42/EC
YES
Powder filling station
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Zone 1
Zone 2
System without pressure
Flexible bag holder
and sealing
Open/close of
powder supply
Pressure build up and
quick exhaust valve
Redundant signal cable
for quick exhaust valve
Powder filling station
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Zone 1
Zone 2
Zone 1
Zone 2
System under pressure
and working
Redundant signal cable
for quick exhaust valve
Powder filling station
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Zone 1
Zone 2
Zone 1
Zone 2
System under pressure
and working
Emergency stop or
signal missing
Powder filling station
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Zone 1
Zone 2
Zone 1
Zone 2
System partly under
pressure and working
1. Actuator for powder
supply exhausting and
closing
2. Bag holder and sealing
still working
Powder filling station
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Zone 1
Zone 2
Zone 1 System partly under
pressure and working
1. Powder supply closed
2. Bag sealing still working
Safe operation according to
“PL e” possible
Further information
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Safety poster
Safety engineering brochure
Contact Data
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Thomas Schulz
Head of Key Account Management
and Industry Segment Management
Biotech/Pharma/Cosmetics
+49 (0) 711 347 52192