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Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. Rev 5058-CO900D T87 – Machinery Safety System Selection & Development Methods Dan Dinunzio Commercial Engineering FS Eng (TÜV Rheinland, #7411 / 13, Machinery)

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Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900D

T87 – Machinery Safety System Selection & Development Methods

Dan DinunzioCommercial EngineeringFS Eng (TÜV Rheinland, #7411 / 13, Machinery)

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Session Purpose and Intent

This session is meant to outline the steps of developing machinery safety solutions and tools that can help reduce the time to develop, implement and start up a machinery safety system.

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Agenda

3

Closing & Wrap-up

Sample Project Utilizing the tools

Selection, Design, Verification, Development & Justification Tools

Safety Life-cycle Utilization

Safety System Development Process

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Safety System Development Process

4

Common Safety System Development Process Machine review & hazard

identification Product Selection Safety System Design Safety System Installation Start Production

Proper Safety System Development Process Risk Assessment Functional Specification

Development Product Selection Structure Selection Design Design Verification Installation Verification & Validation Training Operation & Maintenance

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Most people use the common approach!

5

Most people only analyze automatic operations! Fact – 60 to 70% of all injuries occur outside of normal production activities.

Most people identify hazards and immediately select safety devices/solution without considering the effects on productivity! The number 1 cause of safety system failures is because the solution is

bypassed. This happens because it was not designed to accommodate job tasks.

Most safety systems that follow the common process result in significant reductions in equipment utilization!

Most people have never been to a training session or have never read a machinery safety standard! This results in safety systems that are inadequate, ineffective & improperly designed.

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

The Proper Approach: A standards based methodology!

6

Both EN, ISO and ANSI standards require a systematic approach for safety system development! The first step is the risk assessment.

S1

S2F2

F1

abb

P1P2

e

cc

dd

P1P2P1P2P1P2

F2

F1

bb

cc

dd

ORThe New ANSI TR Method EN/ISO Method

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Development Considerations!

• What machine/machines are to be guarded?• What are the characteristics and limits of

the machine/machines?• What are the different modes of operation

of the machine/machines?• Who interacts with these machines during

normal and abnormal operation?• What are those people doing?• How does the machine need to function in

each mode of operation?• Are these any special system needs?• What type of diagnostics is needed?• What type of system performance is

needed?• What is the target efficiency rate of the

machine/machines?• What is the company specification?• What can be done to improve safety and

productivity?

What do I need to consider?

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Agenda

8

Closing & Wrap-up

Sample Project Utilizing the tools

Selection, Design, Verification, Development & Justification Tools

Safety Life-cycle Utilization

Safety System Development Process

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

The Rockwell Automation approach follows the “Safety Life Cycle”

9

1. Assessment

The Machinery Safety Lifecycle is a defined process that is followed to ensure that proper safety practices have been implemented!

5. Operate, Maintain & Improve

4. Installation & Validation 2. Functional

Requirements

3. Selection, Design & Verification

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Rockwell Automation follows the safety lifecycle to evaluate machinery safety solutions because:

• It remove uncertainty and eliminates omissions and errors!• It provide a repeatable process that leads to complete safety

solutions.

An idea without a plan leads to indecision, omissions and mistakes!

Rockwell’s Safety Life-cycle

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 11

Step 1 in the Machinery Safety Lifecycle is the Assessment!

5. Operate, Maintain & Improve

1. Assessment

4. Installation & Validation 2. Functional

Requirements

3. Selection, Design & Verification

Proper safety system development starts here!

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

What is an assessment and how do I do it?

Step 1: The assessment. The foundation of safety system development!

Machine Characteristics/Limits

Risk Evaluation

Hazard Identification

Risk Estimation

Risk Reduction

Risk Tolerable

OK

Too High

Risk Assessment Process according to ISO12100

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Rockwell Automation developed a Scalable Assessment Process to help our customers!Conformity Audits

& Use of Work Ausits

Hazard Assessment Safety Assessment Team-Based Risk Assessment

Multiple Machines / Plant Wide Machine

Assessment

Identifies Primary Hazards

Used with simple machines

Assessment / EvaluationMultiple Machines, Multiple Sites

Used with semi-complex machines

Detailed Risk Assessment

Used with complex machines

Provides a scalable solution to help save $Range from $125 to $200 per Machine

Identifies guarding/ hazards for immediate plant actions

$1000 per machine

Most common – provides report & provides remediation

recommendations$3500 per machine

In-depth analysis required for critical or special machines

$7000 per machine

• Provides customers with a method of categorizing & prioritizing machines

• Conformity audits that analyze guarding, LOTO, e-stops and circuit review and provides a list of complying & non-complying machines to be assessed

• Use of work that provides mitigation solutions for simple machines

Provides a rapid approach to identifying point-of-operation and power transmission hazards, and identifying appropriate and effective safeguarding measures for reducing risk and exposure

Report Identifying Hazard exposure Estimated risk parameters and

risk reduction Category / Performance level

per standards Potential safeguard or risk

mitigation solution

• Assessment led by RA Consultant, limited customer involvement. Typically operations / maintenance

• Report per standard Identification of primary

hazards/tasks List non-compliance issues Risk In / Risk Out Rating Mitigation Guarding and Controls

recommendations Prioritized recommendations for

safety improvements Photograph of critical identified

hazards (based on customer approval)

• Team-based assessment led by RA, team typically consists of operations, maintenance, engineering, technicians, set up personnel, etc. Report per standards Identification of primary hazards/tasks List non-compliance issues Risk In / Risk Out Rating Mitigation Guarding and Controls

recommendations Prioritized recommendations for safety

improvements Photograph of critical identified

hazards (based on customer approval)

• Mitigation Drawing• Consult for all machine life phases – start

up, normal / abnormal operation, set up, maintenance, product changeover, Copyri

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 14

5. Operate, Maintain & Improve

1. Assessment

4. Installation & Validation 2. Functional

Requirements

3. Selection, Design & Verification

Step 2 in the Machinery Safety Lifecycle is the safety requirements specification!

The SRS defines the functional requirements of the safety system!

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

The main reason for developing a functional spec!

The SRS defines my solution!

• It identifies how the machine is to operate in each mode of operation for each person that interacts with the machine!

• It identified special needs like: (Safe-speed/Safe-direction/Zone control/Etc.)

• It also identifies any special diagnostics and interface needs!

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 16

5. Operate, Maintain & Improve

1. Assessment

4. Installation & Validation 2. Functional

Requirements

3. Selection, Design & Verification

Step 3 is the selection, design & design verification phase.

This step focuses on safety system design, product selection, circuit selection and design verification!

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

My assessment & requirements spec sure made this easy!

The design phase includes selection of mitigation techniques, products, circuit designs & system structure determination!

Design considerations:• What mitigation technique should I use?• What circuit structure should I use?• What safety products should I use?• What type of control system should I use?

(Relays/Controllers/PLC’s)• What type of special operations do I need?

(Zone control/Safe-speed/etc.)• Where are all of my safety devices?• What kind of interactions are needed for

auxiliary machines?• What kind of diagnostics do I need?• Should I use hardwiring or networked

systems?

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

18

Possible Mitigation Techniques!

Design it out

Fixed enclosing guard

Monitoring Access / Interlocked Gates

Awareness Means, Training and Procedures

(Administrative)Personal protective

equipment

Most Effective

Least Effective

Hierarchy of Protective Measures

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Types of Categories (Structures)

19Copyright © Rockwell Automation, Inc. All rights reserved.

CAT B/1 CAT 2

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

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Product Selection Options!

The risk assessment tool identified the required performance level and Category that is required for each part/portion of the machine. Use products that meet the required performance level (PLr) and/or the Category level as directed by the risk assessment.

Note: A safety system is made up of the following components: Safety input devices/actuators Safety control/logic devices Safety output devices

Remember your weakest link sets your maximumsystem performance that can be achieved!

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

A complete safety solution is made up of combinations of input, logic and output!

Safety Controllers

Relays Systems

Safety PLCs

VFD’s

Contactors

Servo’s

Input Logic Output

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Safety Relay/Safety Controller/Safety PLC Selection Matrix!

Safety Relays• 1 Zone• Local/Hardwired I/O• Simple Safety Logic• 1 to 2 dual channel Inputs• 2 to 3 outputs

Safety Controllers & Expandable Relays• 1 to 3 Zones• Local & Distributed I/O• Simple & Complex Safety

Logic• 1 to 20 dual channel Inputs• 1 to 20 outputs• Basic Diagnostics thru PLC

Safety PLCs• More Than 3 Zones• Distributed I/O• Simple & Complex Safety &

Standard Logic• 1 to 100 dual channel Inputs• 1 to 100 outputs• Advanced HMI Diagnostics

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Safety Output Selection

Safety Contactors & Relays• Simple on/off control• Power control• Signal control

Safety Variable Frequency Drives• On/off control with the ability

to control & monitor speed

Safety Servo Systems• On/off control• Speed control• Direction control• Position control• Location control• Acceleration control• Decceleration control

Keep in mind that you have to consider all source of energy that can cause the hazard!

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

How do I verify my design!

The design phase also includes design verification!

Design verification considerations:• What do I need to do to verify my design?• What is meant by system structure?• What product information do I need?• Where do I get product safety data?• What verification tool should I use?

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Design Verification Methods Option 1 - Calculation Method

25

MTTFd Mean Time to Dangerous FailureLow 0 -10 YearsMedium 10-30 YearsHigh 30-100 Years

DC Diagnostic Coverage = Detected Dangerous Failures / All Dangerous FailuresNone DC < 60%Low 60 < DC < 90%Medium 90 < DC < 99%High DC >99%

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. 26

a

b

c

d

ePerfo

rman

ce Le

vel

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

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Design Verification Methods Option 2 - SISTEMA Method

27

SISTEMA is a free design verification tool that isinternationally recognized!

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Design Verification MethodsOption 3 – SAB & SISTEMA Method

28

SAB utilizes SISTEMA for design verification but simplifies theprocess by using menus and questions to populate the data!

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 29

5. Operate, Maintain & Improve

1. Assessment

4. Installation & Validation 2. Functional

Requirements

3. Selection, Design & Verification

Step 4 ensures that the system was installed properly and that the system functions as intended!

This step focuses on ensuring that the safety system was installed properly and that there is a defined process for validating system performance!

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

How do I install my safety system?

Step 4 - Installation• Installation considerations:

• There should be specific instructions regarding physical barrier installation!

• There should be specific instructions regarding safety product installation and wiring!

• There should be specific instructions regarding wiring methods and grounding!

• There should be specific instructions regarding panel fabrication and wiring!

• There should be specific instructions regarding signage installation and location!

• There should be specific layout drawings showing a routing, mounting and installation instructions!

• There should be specific electrical schematics regarding terminations & connections.

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

How do I validate my safety system?

• Verification & Validation considerations:• There should be specific instructions

regarding the verification of each safety function!• This means that each safety input, logic

& output device must be tested to ensure it functions as intended!

• This means that each combined function of input/logic/output must be tested to ensure that it functions as intended!

• This means that each programmed function is verified to ensure it functions as intended!

• There should also be specific instructions regarding validation-fault injection to test the safety system!• Common testing methods include:

• Shorting wires, breaking connections, removing wires, etc.

Step 4 Continued – Verification & Validation

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 32

5. Operate, Maintain & Improve

1. Assessment

4. Installation & Validation 2. Functional

Requirements

3. Selection, Design & Verification

Step 5: Operate, maintain and improve ensures that the system is operated properly and that the system is

maintained to ensure continued effectiveness!

Step 5 focuses on ensuring that the safety system is operating properly and maintained to ensure continued effectiveness!

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

How do I operate my machine?

Step 5 – Operate, Maintain & Improve

• The should be training for all personnel that will be interacting with the machine.

• The training should include:• Intended use• Safety system components training• Normal operations• Abnormal operation• Safety system functionality

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

How do I maintain my safety system?

Step 5 – Operate, Maintain & Improve

• The standards say that periodic testing should be done to verify proper system functionality. (There is no defined period or timeline that is suggested)

• The standards also require additional assessments after machine modifications. This might include:• Program changes• Speed changes• Hardware changes• Machinery changes• System modifications

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 35

5. Operate, Maintain & Improve

1. Assessment

4. Installation & Validation 2. Functional

Requirements

3. Selection, Design & Verification

The Machinery Safety Lifecycle Never Ends!

The circle never ends. The system must be re-evaluated anytime modifications occur and each step must be followed!

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Agenda

36

Closing & Wrap-up

Sample Project Utilizing the tools

Selection, Design, Verification, Development & Justification Tools

Safety Life-cycle Utilization

Safety System Development Process

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Rockwell Automation moved into the number 1 provider of safety solutions because of investment in products, services

& tools that help customers maximize performance!

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Rockwell Automation is investing in all areas of safety to meet customer needs!

• Stand alone safety relay solutions• Modular, expandable & programmable safety

relay solutions • Integrated Safety Solutions

• Embedded Safety Capabilities• Advanced Safe Motion Functions• Integrating Control, Safety & Motion

• CIP Safety for DeviceNet & EtherNet/IP• Low Cost Safety Networks• Dual Port EtherNet/IP

• Safety Actuators & Pushbuttons• Presence Sensing Devices• Interlocking Devices

COMPONENTS

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Rockwell Automation is investing in Services to support our customer needs!

Assessments Arc Flash Analysis Hazard Risk LOTO HAZOP

Validation Safety circuit

analysis Machine stop time

services Conformance

audits Safety system

validation

Compliance Consulting CE conformance Functional safety

(ex. ISO 13849-1 and IEC 62061, ISO, ANSI, IEC, CE, OSHA, NFPA, CSA, AS ) 200+ Safety Professionals Available Globally

100+ Machinery Safety Certified Resources 80+ Process Safety ResourcesOver 200 Training Courses for help customers develop competency

30 + RA Safety Professionals3 RA Safety Partners – 20 Resources

4 Safety Professionals

20+ RA Safety Professionals12 RA Safety Partners – 24+ Resources

20+ Safety Professionals

6 Safety Professionals

5 Safety Professionals

5 Safety Professionals

Training TUV Certification Risk Assessments Safety Standards Safety Products Arc Flash LOTO

Integration / Start Up Circuit/logic design Installation Arc flash

remediation MCC Arc Flash

upgrades Project

Management

Remediation Solutions Complete

Turnkey Systems

The most complete suite of safety services in the industry!

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Rockwell Automation’s investment in tools!

Safety Return-On-Investment ToolFind out how to quantify the savings and productivity gains from safety investments. The Rockwell Automation Safety Return-On-Investment Tool accounts for improved safety, reduced claims, improved productivity, and other issues unique to safety applications.

Safety Functions

Safety Functions ProgramThe Safety Functions Program is building block approach to designing safety systems. Each building block has a complete documentation package that includes a description of each safety function, an electrical schematic, a bill of material, a SISTEMA verification calculation and a verification and validation plan.

SABSafety Automation BuilderThe Safety Automation Builder software package that allows users to import images of their machines. Users can identify hazardous access points and the associated hazards in order to develop a list of safety products that will be used to mitigate the risk. This gives the customer a complete drawing, a bill of material and SISTEMA calculation.

Safety Accelerator

Toolkit

Safety Accelerator Toolkit This toolkit provides easy to use system design, programming, and diagnostic tools to assist you in the rapid development and deployment of your safety systems using GuardLogix, Compact GuardLogix, or SmartGuard 600 Controllers, Guard I/O, and Safety Devices. The toolkit includes a risk assessment and system design guide, hardware selection guide, CAD drawings, safety logic routines, and operator status and diagnostic faceplates.

Connected Components

BB

Connected Components Building BlocksThese building blocks are tools that help customers develop safety solutions that utilize component class safety solutions. These building blocks include sample programs, electrical schematics and configuration document that help in the

ProSafeBuilder

ProSafe BuilderThe ProSafe Builder software gives users the ability to layout complete trapped key solutions for machinery safety applications with a tool that generate a bill of material and system configuration schematic/map.

The broadest suite of safety tools in the industry!

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Safety System Development Tools

41

SABSafety Automation BuilderThe Safety Automation Builder software package that allows users to import images of their machines. Users can identify hazardous access points and the associated hazards in order to develop a list of safety products that will be used to mitigate the risk. This gives the customer a complete drawing, a bill of material and SISTEMA calculation.

ProSafeBuilder

ProSafe BuilderThe ProSafe Builder software gives users the ability to layout complete trapped key solutions for machinery safety applications with a tool that generate a bill of material and system configuration schematic/map.

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

What is Safety Automation Builder (SAB)?

SAB is a new tool designed to help develop complete safety system solutions. These solutions include conceptual layout drawings that includes zones, physical guards, hazards, access points and the products used to protect personnel.

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

SAB helps tie the two sides of Functional Safety together by providing a method to select the safety products that are required to complete a safety solution!

Risk Assessment Design Verification

Determines (PLr) Confirms PLr Achieved

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Qty Catalog Number Description DS List Ea Typical Delivery

1 445L‐P4E0600FPMicro 400 Safety Light Curtain, Pair, Res 30mm, Pt Ht 600mm E8 $  1,220.00  Preferred

2 445L‐AC8RJ5 M12 to RJ45, 5 meter E8 $        26.30  Preferred

1 440R‐ACABL2 Ribbon cable 10 pin for 2 extenstion E8 $        36.46 

1 440R‐P226AGS‐NNRMSR42 Multi function Controller for GuardShield Light Curtains E8 $     507.00  Preferred

1 440R‐D22R2

Guardmaster Safety Relay, 2 Dual Channel Universal Inputs, 1 N.C. Solid State Auxiliary Outputs E8 $     402.99  Preferred

1 100S‐C37EJ14BCMCS 100S‐C Safety Contactor, 37A, 24V DC (w/Elec. Coil), Bifuracated Contact B7 $     411.07 

1 1754‐L28BBBGuardPLC 1200 ‐ Packaged Safety Controller, 28 I/O D5 $  6,120.60 

1 1753‐DNSI GuardPLC DeviceNet Safety Scanner D5 $  1,141.30 

2 1753‐IB16 Digital Input Module, 16 Inputs, 24V DC D5 $  1,787.70  Preferred

SAB – The Complete Safety System Design & Verification Tool That Leaves Customer With A Complete Bill Of Material!

Complete Safety System Layout

Performance LevelVerification

Complete Bill of Material

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

ProSafe Builder - Trapped Key Configuration Software

4

The software will allow users to layout trapped key systems in a systematic method that shows a flow view of configured and selected products.

The comprehensive trapped/captive key tool on the market!

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Safety System Investment Justification Tool

46

Safety Return-On-Investment ToolFind out how to quantify the savings and productivity gains from safety investments. The Rockwell Automation Safety Return-On-Investment Tool accounts for improved safety, reduced claims, improved productivity, and other issues unique to safety applications.

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Justification Of Safety Investments

47

So, how do I justify a safety investments on my machine?A. Based on the costs of an incident that could be avoidedB. You don’t; Just do the minimum to comply with a standardC. Based on the potential for productivity improvementD. Based on the fine from a non-compliance finding E. Perform an ROI

Answer: “E”

Good News! Rockwell Automation Can Help With A Safety ROI Calculator

“But how do I calculate a Safety ROI?”

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

What is the Safety ROI Calculator Tool?

48

The industries only return on investment tool for safety projects!

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

ROI Example Output!

49

The Safety ROI tools helps customers justify safety projects based on project cost and injury avoidance calculations!

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Safety System Design Tools

50

Safety Functions

Safety Functions ProgramThe Safety Functions Program is building block approach to designing safety systems. Each building block has a complete documentation package that includes a description of each safety function, an electrical schematic, a bill of material, a SISTEMA verification calculation and a verification and validation plan.

Safety Accelerator

Toolkit

Safety Accelerator Toolkit This toolkit provides easy to use system design, programming, and diagnostic tools to assist you in the rapid development and deployment of your safety systems using GuardLogix, Compact GuardLogix, or SmartGuard 600 Controllers, Guard I/O, and Safety Devices. The toolkit includes a risk assessment and system design guide, hardware selection guide, CAD drawings, safety logic routines, and operator status and diagnostic faceplates.

Connected Components

BB

Connected Components Building BlocksThese building blocks are tools that help customers develop safety solutions that utilize component class safety solutions. These building blocks include sample programs, electrical schematics and configuration document that help in the

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.5151

Safety Life Cycle

5. Maintain and Improve

1. Hazard or RiskAssessment

4. Installation and Validation 2. Functional Safety

System Requirements3. Design and Verification

Identify Hazards &estimate theassociated risk

System ArchitectureSafety critical circuit designGuarding designValidation protocol

Based on:- Risk Assessment- system performance- applicable s standards

Final site assemblyCommissioning/ValidationTrainingFinal Risk Assessment Validation

Verify that system requirementsoperate within specified parameterfor Production and SafetyPreventative maintenance and system upgrades

Safety Functions help customers move beyond the risk assessment with complete Rockwell solutions!

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Safety Functions are the building blocks of machinery safety solutions!

Risk Assessment Model & Confirm PLr

Determines (PLr) Confirms PLr Achieved

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

The more complicated the machine the mores safety functions you need!

E-Stop Device 1

E-Stop Device 2

Light Curtain 1

Door Interlock 1

Logic

Output 1

Output 2

Output 3

SF1

SF2

Logic

SF3

SF4 Output 4Logic

Logic

Large and complex machines may require multiple safety functions to provide a complete machine safety solution. Safety function documents are 1 way that Rockwell Automation can help!

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. 54

Sample Safety FunctionSafety Function: Emergency Stop Products: Light Curtain / GuardLogixSafety Rating: PLe, Cat. 4 to EN ISO 13849.1 2008

.

IntroductionImportant User InformationGeneral Safety InformationSafety Function RealizationSetup and WiringConfigurationProgrammingFalling Edge ResetCalculation of PFHdVerification and Validation PlanAdditional Resources

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

IA Safety Accelerator ToolkitDevelopment Tools and Quick Start Guide

Simplified Wiring

Preconfigured LogicQuick Start Manual

Preconfigured HMI

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

IA Safety Accelerator ToolkitSafety Application Examples

56

Example Code

I/O Configuration

Diagnostics

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Instruction Faceplates

57

Want to troubleshoot safety instructions from your HMI? NOW YOU CAN

Display the instruction as the Function it is performing. Estop Light Curtain Light Curtain Muting Etc.

57

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Safety Accelerator ToolkitGuard I/O Status and Diagnostic Faceplates

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Safety Performance Tools for GuardLogix

TUV Recognized Analysis Tools Single Channel Safety Reaction Time Tool Network Reaction Time Tool

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

GuardLogix Safety Estimator

Safety Tool to help estimate system performance and network configuration.

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Connected Component Building Blocks for Safety

61

Pre-designed Building Blocks with source code, drawings and quick-start guide to help you develop safety solutions!

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Agenda

62

Closing & Wrap-up

Sample Project Utilizing the tools

Selection, Design, Verification, Development & Justification Tools

Safety Life-cycle Utilization

Safety System Development Process

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

The Safety Process – What do I do?

63

Ok, I need to make my machine safe. Now what? Four Questions To Navigate the Jungle

What do I need to do? What are my options? How much do they cost? Which option is right for me?

Let’s Look At A Couple Of Options…

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Let’s look at a sample machine!

64

We are going to use the safety tools to develop a safety solution utilizing Safety Automation Builder. This will leave us with a concept drawing, a design verification and a complete bill of material.

We will use the ROI tool to help the customer justify the project. We will then search for solutions for the selected products using safety

functions, safety accelerator toolkit and connected components building blocks.

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Machine Description

65

Infeed Conveyor

OutfeedConveyor

Rotary Table

Label P&P

Label Feeder

Hot Glue GunProduct

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Step 1 – Risk Assessment

66

We are going to develop a risk assessment utilizing the ISO12100 evaluation method.

S1

S2F2

F1

abb

P1P2

e

cc

dd

P1P2P1P2P1P2

F2

F1

bb

cc

dd

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Step 1 Details

67

Normal operation Maintenance Set-up Adjustment Change-over Start-up Decommissioning Etc.

Identify the hazards and associated risks! Develop a functional specification that outlines how each hazard needs to be protected for each mode of operation.

Thermal Hazard

Crushing Hazard

Pinching Hazard

Pinching Hazard

It is estimated that 60 to 70% of all injuries happen outside of normal production activities yet most people spend 90% of their efforts around designing for production activities!

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. 68

Show how the ISO12100 risk methodology is used to determine the required system performance that is to be implemented.

Step 2 – Functional Specification Development

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Step 2: Write a Functional Specification

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The assessment defined the task and associated hazards and the required system performance that is required.

The function specification will determine the required safety functions, their design requirements and the type of functionality that is needed for each mode of operation for each person that interacts with the machine.

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Next Step Define Our Safety Functions

When Door Opens in zone #1, tray packing stops, zone #2, tray forming continues.

Safety Function: Safety related stop function

initiated by a safe guard Stopping hazardous

movement Triggering Event:

Opening of guard door

Zone #1 Zone #2

Follow This Process for Every Safety Function in Every Machine Mode!

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Step 3: Develop a safety project utilizing Safety Automation Builder.

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This screen shot shows the layout drawing with identified hazard locations and access points that need to be protected!

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Users can now start the safety selection process by selecting input, logic and output devices for each identified safety need!

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This screen shot shows the layout drawings with the selected safety devices!

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Users can view the selected safety devices for each safety function by access point by clicking on the table view!

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This screen shot shows the devices that were selected for each safety function!

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Users can verify their design by exporting the SAB file to SISTEMA for design verification! This is a sample report.

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This screen shot shows the safety design verification report from SISTEMA!

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Completed Bill of Material from ProposalWorks & SAB!

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This screen shot shows the completed bill of material for the labeler machine safety system!

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Now we have a price! We need to justify the investment!

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We will use the Safety Return on Investment Tool to justify the project based on projected reductions of injuries and productivity enhancements!

Let’s calculate our savings and ROI for this machine example!

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The next step after selection, design verification & justification is design!

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Now we need to start making schematics, developing programs and configuration documents. We will guide you to locations that can help!

The Safety Functions documents are found on the safety resource center!

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An additional tool that can help is Safety Accelerator Toolkit

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Safety Accelerator Toolkit

The Safety Accelerator Toolkit can be found on the safety resource center or by asking your local Rockwell distributor!

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

An additional tool that can help is Connected Component Building Blocks for Safety

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The Safety Building Blocks can be found by asking your local Rockwell distributor for a CD!

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Agenda

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Closing & Wrap-up

Sample Project Utilizing the tools

Selection, Design, Verification, Development & Justification Tools

Safety Life-cycle Utilization

Safety System Development Process

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Rockwell Automation the global leader in safety (Services / Products / Solutions)!

Best in class assessment services to help you to determine safety system needs!

Safety Design Tools and resources to help engineers and designers with safety system development.

Products selection and design verification tools to helps engineers select product quickly and accurately.

Installation and start-up services to help meet productivity and start-up needs.

Validation services to ensure that the safety system operates as designed and constructed.

Preventive maintenance development services to ensure the safety system continues to operate properly.

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Questions?

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Then fill in the required information on the survey screen:1. Your Session Code (i.e. T200)2. Your Short Code Located on your

Badge 3. Select “YES”4. Hit “Continue”

To start, scan the QR Code below:

Like what you saw? Request Follow-up from a Rockwell Representative!

Allows attendees to raise their hand and self-identify as a Lead at the end of Technical Sessions & Hands-on Labs