T63 - Safety System Development Process and Configuration Tools Overview

Transcription

1 T63 - Safety System Development Process and Configuration Tools Overview Rev 5058-CO900D Copyright Copyright Rockwell Rockwell Automation, Automation, Inc. Inc. All Rights All Rights Reserved. Reserved.

2 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 design, develop, implement and start up a machinery safety system.

3 3 Agenda Safety System Development Process Safety Life-cycle Utilization Selection, Design, Verification, Development & Justification Tools Sample Project Utilizing the tools Closing & Wrap-up

4 4 Safety System Development Process 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 Safety System Design Design Verification Safety System Installation Verification & Validation Training Start Production Operation & Maintenance

5 5 Most people use the common approach! 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. 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!

6 6 Agenda Safety System Development Process Safety Life-cycle Utilization Selection, Design, Verification, Development & Justification Tools Sample Project Utilizing the tools Closing & Wrap-up

7 7 The Rockwell Automation approach follows the Safety Life Cycle 5. Operate, Maintain & Improve 1. Assessment 4. Installation & Validation 2. Functional Requirements 3. Selection, Design & Verification The Machinery Safety Lifecycle is a defined process that is followed to ensure that proper safety practices have been implemented!

8 Copyright 2011 Rockwell Automation, Inc. All rights reserved. 8 Copyright 2013 Rockwell Automation, Inc. All Rights Reserved. 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!

9 Step 1: The assessment. The foundation of safety system development! What is an assessment and how do I do it? Risk Assessment Process according to ISO12100 and ANSI BB.0 Machine Characteristics/Limits Hazard Identification Risk Estimation Risk Evaluation Too High Risk Reduction OK Risk Tolerable

10 10 The Proper Approach: A standards based methodology! Both EN, ISO and ANSI standards require a systematic approach for safety system development! So which standard is right for you? ANSI/RIA Method S2 S1 E2 E1 E2 E1 A1 A2 A1 A2 A1 A2 A1 R1 R2A R2B R2B R2C R3A R3B R4 OR EN/ISO Method S1 S2 F1 F2 F1 F2 P1 P2 P1 P2 P1 P2 P1 P2 a b b c c d d e Either is OK but the move is towards the ISO methods to global use. ANSI recognizes ISO and IEC standards today. This allows OEM s to have 1 design for worldwide use!

11 Rockwell Automation uses 3 Scalable Assessment Solutions 11 Conformity Audits Guarding Evaluation Risk Assessments Multiple Machines / Plant Wide Machine Audit Provides a High Level Analysis of Specific Safety Areas Provides a high level safety analysis of machine by performing the following: Conformity audit that analyzes guarding, components that perform a safety function, e- stops, LOTO and / or isolation devices are identified and labeled Existing safety circuit estimation Provides a method for identifying conforming and non-conforming machinery. Provides a method to prioritize machines for further assessment Identifies Primary Guarding Hazards Identifies guarding hazards for immediate plant actions 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 Category / Performance level per standards Potential safeguard or risk mitigation solution Basic Safety Assessment or Team Based Risk Assessment (TBRA) Basic Safety Assessment - provides analysis using limited customer personnel Team Based Risk Assessment - In-depth analysis required for critical or special machines Basic Assessment - provides analysis using limited customer personnel Assessment by RA Safety Engineer / Consultant, limited customer involvement. (Typically operations / maintenance) Assessment report includes: - Documentation of participants - Identification of primary hazards / tasks - Risk In / Risk Out Rating - Recommendations for safety improvements, such as: Protective Guarding; Electrical Safety Controls; Pneumatic / Fluid Power Safety Controls Safety circuit performance requirements Photograph of critical identified hazards (based on customer approval) Team Based Risk Assessment - In-depth analysis required for critical or special machines All features of the Basic Safety Assessment plus the following additional features: Team-based assessment facilitated by RA Safety Engineer / Consultant Customer team typically consist of operations, maintenance, engineering, technicians, cleaning, sanitation & safety personnel Basic risk assessment training Hazard identification during setup, normal and abnormal operation, sanitation / cleaning, maintenance (under limited energy), emergency conditions Report documentation includes all elements from Safety Evaluation with additional information: - Plan view machine layout with recommended safety improvements - Limits of machine - Incident/accident history - This service can satisfy the risk assessment requirements of safety standards (i.e. OSHA, ANSI, CE Machinery Directive, ) Copyright 2013 Rockwell Automation, Inc. All Rights Reserved. Copyri

12 Copyright 2011 Rockwell Automation, Inc. All rights reserved. 12 Copyright 2013 Rockwell Automation, Inc. All Rights Reserved. Step 2 in the Machinery Safety Lifecycle is the safety requirements specification! 5. Operate, Maintain & Improve 1. Assessment 4. Installation & Validation 2. Functional Requirements 3. Selection, Design & Verification The SRS defines the functional requirements of the safety system!

13 Step 3 is the selection, design & design verification phase. 5. Operate, Maintain & Improve 1. Assessment 4. Installation & Validation 2. Functional Requirements 3. Selection, Design & Verification This step focuses on safety system design, product selection, circuit selection and design verification! Copyright 2011 Rockwell Automation, Inc. All rights reserved. 13 Copyright 2013 Rockwell Automation, Inc. All Rights Reserved.

14 The design phase includes selection of mitigation techniques, products, circuit designs & system structure determination! My assessment & requirements spec sure made this easy! Design considerations: What mitigation technique should I use? What products allow this functionality? What circuit structure 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? The following slides are going to take a deeper look!

15 Possible Mitigation Techniques! Hierarchy of Protective Measures Design it out Most Effective Fixed enclosing guard Monitoring Access / Interlocked Gates Awareness Means, Training and Procedures (Administrative) Personal protective equipment Copyright 2007 Rockwell Automation, Inc. All rights reserved. Least Effective Copyright 2013 Rockwell Automation, Inc. All Rights Reserved. 15

16 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 maximum system performance that can be achieved!

17 Cables & Distr. Blocks Component level Information level Indicators Valves Servo Motion Drives Contactors DIO PLC Configurable Relays E-Stop Cable Pull Two-Hand PB Enabling Edges Mats Trap Key Ple Locking Key Interlock Non-Contact (RFID) Camera Laser Scanner Light Curtain Global Market Leaders A complete safety solution is made up of combinations of input, logic and outputs! Input Devices Logic Devices Output Devices Network & Connectivity #1 Rockwell #2 #3 #4 #5 Fully capable Offered but limited No offering Offered through partner Out complete portfolio is our key differentiator. Copyright 2013 Rockwell Automation, Inc. All Rights Reserved.

18 We also have the most Scalable Safety Logic Solutions in the market. Basic Safety Solutions Modern Safety Solutions Contemporary Solutions Simple connectivity Mechanical linked machine Stand alone machine Low cost Just enough control Low Multi-axis motion Increased controller capabilities Mix of mechanical and electrical controls Low engineering costs Integration Continuum Coordinated multi-axis motion Robotic feeders Electronic line shafting Advanced connectivity Advanced information capabilities High Offering solutions that fit your needs, not ours! Copyright 2011 Rockwell Automation, Inc. All rights reserved. Copyright 2013 Rockwell Automation, Inc. All Rights Reserved. 18

19 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 Little to no motion Safety PLCs More Than 3 Zones Distributed I/O Semi-complex & Complex Safety & Standard Logic 1 to 100 dual channel Inputs 1 to 100 outputs Advanced HMI Diagnostics Multiple axes of motion Safety Controllers & Expandable Relays 1 to 3 Zones Local & Distributed I/O Simple & Complex Safety Logic 1 to 10 dual channel Inputs 1 to 10 outputs Basic Diagnostics thru PLC Up to 6 axes of motion

20 Safety Output Selection Matrix 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

21 The design phase also includes design verification! How do I verify my design! Design verification considerations: What is meant by system structure? What is system reliability? What is diagnostic coverage? Where do I get the product safety data? What verification tool should I use?

22 The 1 st design Verification Consideration is what types of structure are you going to use? CAT B/1 CAT 2 CAT 3 CAT 4 (higher diagnostic coverage that CAT 3) Copyright Rockwell Automation, Inc. All rights reserved. Copyright 2013 Rockwell Automation, Inc. All Rights Reserved.

23 23 The 2 nd and 3 rd steps of design verification includes calculating the MTTFd and DC of the system. MTTFd Mean Time to Dangerous Failure Low 0-10 Years Medium Years High Years DC Diagnostic Coverage = Detected Dangerous Failures / All Dangerous Failures None DC < 60% Low 60 < DC < 90% Medium 90 < DC < 99% High DC >99%

24 Performance Level Copyright 2013 Rockwell Automation, Inc. All Rights Reserved. Confirming PL is achieved by Balancing Structure (Cat), Reliability (MTTFd) and Diagnostic Coverage (DCavg) a b c d e Structure (Category) 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 Diagnostic Coverage (DC) DC avg DC avg DC avg DC avg DC avg DC avg DC avg <60% <60% Reliability (MTTF) 60% to < 90% 90% to < 99% 60% to < 90% 90% to < 99% 99%

25 Copyright 2011 Rockwell Automation, Inc. All rights reserved. 25 Copyright 2013 Rockwell Automation, Inc. All Rights Reserved. The next phase includes validating that the safety system operates as intended. 5. Operate, Maintain & Improve 1. Assessment 4. Installation & Validation 2. Functional Requirements 3. Selection, Design & Verification This step focuses on ensuring that the safety system was installed properly and that there is a defined process for validating system performance!

26 Copyright 2011 Rockwell Automation, Inc. All rights reserved. 26 Copyright 2013 Rockwell Automation, Inc. All Rights Reserved. The final step covers Operation & maintenance to ensure that the system remains functional 5. Operate, Maintain & Improve 1. Assessment 4. Installation & Validation 2. Functional Requirements 3. Selection, Design & Verification Step 5 focuses on ensuring that the safety system is operated properly and maintained to ensure continued effectiveness!

27 Copyright 2011 Rockwell Automation, Inc. All rights reserved. 27 Copyright 2013 Rockwell Automation, Inc. All Rights Reserved. The Machinery Safety Lifecycle Never Ends! 5. Operate, Maintain & Improve 1. Assessment 4. Installation & Validation 2. Functional Requirements 3. Selection, Design & Verification The circle never ends. The system must be re-evaluated anytime modifications occur and each step must be followed!

28 28 Agenda Safety System Development Process Safety Life-cycle Utilization Selection, Design, Verification, Development & Justification Tools Sample Project Utilizing the tools Closing & Wrap-up

29 29 Another way of doing Design Verification is using a software called SISTEMA SISTEMA is a free design verification tool that is internationally recognized!

30 30 Rockwell created a new safety selection tool that utilizes SISTEMA for verification SAB utilizes SISTEMA for design verification but simplifies the process by using menus and questions to help with selection!

31 Rockwell Automation s investment in tools! SAB ProSafe Builder Safety Automation Builder The 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. ProSafe Builder The 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. Safety Return-On-Investment Tool Find 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 Accelerator Toolkit Connected Components BB Safety Functions Program The 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 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 Building Blocks These 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 The broadest suite of safety tools in the industry! Copyright 2013 Rockwell Automation, Inc. All Rights Reserved.

32 32 Safety System Development Tools SAB Safety Automation Builder The 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. ProSafe Builder ProSafe Builder The 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.

33 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.

34 34 Safety System Investment Justification Tool Safety Return-On-Investment Tool Find 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.

35 35 ROI Example Output! The Safety ROI tools helps customers justify safety projects based on project cost and injury avoidance calculations!

36 36 Safety System Design Tools Safety Functions Safety Accelerator Toolkit Connected Components BB Safety Functions Program The 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 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 Building Blocks These 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

37 Safety Functions are the building blocks of machinery safety solutions! Risk Assessment Model & Confirm PLr Determines (PLr) Confirms PLr Achieved

38 The more complicated the machine the mores safety functions you need! SF1 E-Stop Device 1 Logic Output 1 SF2 E-Stop Device 2 Logic Output 2 SF3 Light Curtain 1 Logic Output 3 SF4 Door Interlock 1 Logic Output 4 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!

39 39 Safety Function Documents Safety Function: Emergency Stop Products: Light Curtain / GuardLogix Safety Rating: PLe, Cat. 4 to EN ISO Introduction Important User Information General Safety Information Safety Function Realization Setup and Wiring Configuration Programming Falling Edge Reset Calculation of PFHd Verification and Validation Plan Additional Resources

40 IA Safety Accelerator Toolkit Development Tools and Quick Start Guide Preconfigured Logic Quick Start Manual Simplified Wiring Preconfigured HMI

41 41 Connected Component Building Blocks for Safety Pre-designed Building Blocks with source code, drawings and quick-start guide to help you develop safety solutions!

42 42 Agenda Safety System Development Process Safety Life-cycle Utilization Selection, Design, Verification, Development & Justification Tools Sample Project Utilizing the tools Closing & Wrap-up

43 43 Let s look at a sample machine! 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.

44 44 Machine Description Outfeed Conveyor Rotary Table Label P&P Label Feeder Infeed Conveyor Product Hot Glue Gun

45 45 Step 1 Risk Assessment We are going to develop a risk assessment utilizing the ISO12100 evaluation method. S1 S2 F1 F2 F1 F2 P1 P2 P1 P2 P1 P2 P1 P2 a b b c c d d e

46 46 Step 1 Details 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 Normal operation Maintenance Pinching Hazard Set-up Adjustment Change-over Start-up Decommissioning Pinching Hazard Etc. Crushing 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!

47 47 Step 2: Write a Functional Specification 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.

48 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!

49 Step 3: Develop a safety project utilizing Safety Automation Builder. This screen shot shows the layout drawing with identified hazard locations and access points that need to be protected! Copyright 2013 Rockwell Automation, Inc. All Rights Reserved. 49

50 50 Users can now start the safety selection process by selecting input, logic and output devices for each identified safety need! This screen shot shows the layout drawings with the selected safety devices!

51 51 Users can verify their design by exporting the SAB file to SISTEMA for design verification! This is a sample report. This screen shot shows the safety design verification report from SISTEMA!

52 Completed Bill of Material from ProposalWorks &SAB! This screen shot shows the completed bill of material for the labeler machine safety system! Copyright 2013 Rockwell Automation, Inc. All Rights Reserved. 52

53 53 Now we have a price! We need to justify the investment! 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!

54 54 The next step after selection, design verification & justification is design! 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!

55 55 An additional tool that can help is Safety Accelerator Toolkit Safety Accelerator Toolkit The Safety Accelerator Toolkit can be found on the safety resource center or by asking your local Rockwell distributor!

56 56 An additional tool that can help is Connected Component Building Blocks for Safety The Safety Building Blocks can be found by asking your local Rockwell distributor for a CD!

57 57 Agenda Safety System Development Process Safety Life-cycle Utilization Selection, Design, Verification, Development & Justification Tools Sample Project Utilizing the tools Closing & Wrap-up

58 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.

59 Questions? Rev 5058-CO900D Copyright Copyright Rockwell Rockwell Automation, Automation, Inc. Inc. All Rights All Rights Reserved. Reserved.