Safety Update

1. This presentation covers • Machinery Directive 2006/42/EC • BS/EN954-1 • EN ISO 13849-1 • EN/IEC 62061 Safety Update

2. Machinery Directive 2006/42/EC • Process of Risk Assessment • EN ISO 12100–2:2003 Safety of Machinery.Technical principles • Machine manufacturers are obligated to complete a Risk Assessment that is now defined within the directive as an iterative process of hazard identification, risk estimation, hazard elimination or risk reduction. • Safety system requirements • Machine designers are obligated to design control systems in such a way that a fault in the hardware or software of the control system and/or reasonably foreseeable human error does not lead to hazardous situations Introduction

3. BS/EN954-1 Valid up to 29th December 2009 (Update from beginning September ’09: EN954-1 has been given a stay of execution until the end of 2011) • EN ISO 13849-1 is applicable for electrical/electronic/programmable electronic/hydraulic/pneumatic/mechanical systems. • EN/IEC 62061 is applicable for electrical/electronic/programmable electronic systems Current status

4. BS/EN954-1 was used for all safety systems using standard control circuits and tried and tested equipment. Higher levels of safety achieved by monitoring at various stages, once per shift, every reset etc. • EN ISO 13849-1 is applicable for: electrical/electronic/programmable electronic/hydraulic/pneumatic/mechanical systems. • EN/IEC 62061 is applicable for electrical/electronic/programmable electronic systems Usage of different standards

5. BS/EN954-1 Categories B,1,2,3,4 Safety Categories EN945-1

6. EN ISO13849-1 Performance Levels a-e Safety Categories EN13849-1

7. IEC/EN 62061 is the machine sector specific standard within the framework of IEC/EN 61508. EN 62061 is harmonised under the European Machinery Directive. • The Safety Integrity Level (SIL) is the new measure defined in IEC 61508 regarding the probability of failures in a safety function or a safety related system. • For machinery, the probability of dangerous failures per hour of a control systemis denoted in IEC/EN 62061 as the PFHd Safety Categories EN62061

8. } Frequency and duration of exposure Probability of occurrence of that harm Risk related to the identified hazard Severity of the possible harm Fr = and Probability of occurrence of a hazardous event Pr Se Probability of avoiding or limiting harm Av • EN/IEC 62061 requires each safety function to be assessed in the following manner • The required risk assessment graph is shown on the following pages Safety Categories EN62061

9. Machinery: Risk parameter examples of IEC/EN 62061 • List all the possible hazards of the machine and • Determine the parameters according to the tables and fill in the values: The Class Cl is the sum of: Fr + Pr + Av = Cl Safety of Machinery and Functional Safety

10. + + = • Machinery: Determination of the required SIL (Safety Integrity Level). Example according to IEC/EN 62061 Safety of Machinery and Functional Safety

11. Machinery: Risk assessment form given as an example in IEC/EN 62061

12. SIL calculations can be approximately converted over to PL levels… • The relationship between the categories, the PL and the SIL is as follows: Not more than 1 dangerous failure of the safety function in 10 years Not more than 1 dangerous failure of the safety function in 100 years Not more than 1 dangerous failure of the safety function in 1000 years Safety Level Comparison

13. To enable the value of PL or SIL to be calculated information must be available from equipment manufacturers. • Software Packages available to help with verification of PL or SIL £ PILZ Pascal £ SIEMENS “The Safety Evaluation Tool” online package FREE! SISTEMA German BGIA organisation tool for calculating Performance Level to EN ISO 13849-1 Calculation of PL and SIL

14. Example calculation - Risk assessment for a rotary printing machine • On a web-fed printing press, a paper web is fed through a number of cylinders. High operating speeds and rotational speeds of the cylinders are reached, particularly in newspaper printing. Essential hazards exist at the zones where it is possible to be drawn in by the counter-rotating cylinders. This example considers the hazardous zone on a printing machine on which maintenance work requires manual intervention at reduced machine speeds. The access to the hazardous zone is protected by a guard door (safeguarding). The following safety functions are designated: • SF1 — Opening of the guard door during operation causes the cylinders to be braked to a halt. • SF2— When the guard door is open, any machine movements must be performed at limited speed. • SF3— When the guard door is open, movements are possible only whilst an inching button is pressed. Entrapment between the cylinders causes severe injuries (S2). Since work in the hazardous area is necessary only during maintenance tasks, the frequency and duration of hazard exposure can be described as low (Fl). At production speeds, no possibility exists of avoiding the hazardous movement (P2). Calculation of PL and SIL Example taken from BGIA report 2/2008e

15. Example calculation - Risk assessment for a rotary printing machine • This therefore results in a required Performance Level PLr Of d for the safety functions SF1 and SF2 • The safety function SF3 can however be used only if the printing machine has first been halted (SF1) and the permissible rotational speed of the cylinders limited (SF2). • This results in the possible machine movements being predictable for the operator, who is thus able to evade hazardous movements (P1). A required performance level PLr of c is therefore adequate for SF3. Calculation of PL and SIL Example taken from BGIA report 2/2008e

16. EN ISO13849-1 is the default choice for systems that contain non-electrical systems and an overall summary is shown below: Conclusions