machine safety symposium - mcnaughton-mckay · - project: refers to machine or summary of safety...
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Copyright © 2016 Rockwell Automation, Inc. All rights reserved.
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Machine Safety
Symposium
Software Tools
Copyright © 2016 Rockwell Automation, Inc. All rights reserved.
EN954 ISO 13849-1Implications of Changing Standards…
• Move towards global safety standards
–EN-954 (Safety Categories) officially withdrawn on January 1, 2012
–EN ISO 13849-1 (Performance Levels) in effect since then
• ISO 13849-1 Specifies circuit performance in terms of
performance levels (PL)–Structure…. Category
–Reliability…. MTTFd
–Monitoring… DC avg
• Risk Assessment criteria are defined and mapped to Required
performance Levels (PLr)–Based on severity, frequency & avoidance
•Risk Assessments evaluate the potential hazards in order to
determine the required performance level.
Two Sides of Functional Safety
Risk Assessment Model & Confirm PLr
Determines (PLr) Confirms PLr Achieved
Sistema Supports Both Sides of Analysis& Provides Critical Documentation
Risk Assessment…A Foundation of Good Engineering Practice
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Machine Characteristics/Limits
Hazard Identification
Risk Estimation
Risk Reduction
Risk Evaluation
OKToo
High
Risk
Tolerable
Next
Hazard
Risk Analysis
Risk Evaluation/Reduction
-Repeatable-Team Based-Task Hazard Oriented-Analyzes
Severity, Frequency, Avoidance-Determines Appropriate PLr
-Mitigation Hierarchy-Solution Based OnStructure, Reliability,
& Monitoring-Confirms PLr is Achieved
Risk Estimation
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ISO 13849 Risk Estimation… Severity
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ISO 13849 Risk Estimation… Frequency
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ISO 13849 Risk Estimation… Avoidance
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PLr
Hierarchy of Risk Reduction Measures
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Achieving PLr
• System Structure…. Category
• Component Reliability….MTTFd
• Monitoring Capability…. Diagnostic Coverage
• Common Cause Failure Analysis… CCF
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Achieving PLr With ISO13849 Flexibility
• System Structure…. Category
• Component Reliability….MTTFd
• Monitoring Capability…. Diagnostic Coverage
• Common Cause Failure Analysis… CCF
Functional Safety Roadmap
1. Determine the Required Performance Level
Perform Risk Assessment considering all hazards
2. Decide on the Architecture/Category
Cat B, 1, 2, 3, 4
3. Collect Data
From vendor documentation or libraries
4. Do the PL Calculation
Manually or leverage software tools
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Types of Categories (Structure)
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CAT B/1 CAT 2
CAT 3 CAT 4 (higher diagnostic coverage that CAT 3)
13849
Functional Safety Roadmap
1. Determine the Required Performance Level
Perform Risk Assessment considering all hazards
2. Decide on the Architecture/Category… Cat B, 1, 2, 3, 4
3. Collect Data… MTTFd… From vendor documentation or libraries
4. Diagnostic Coverage and PL Verification
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%
Utilize SISTEMA Software… www.machinesafetysolutions.com
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a
b
c
d
ePer
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%
Performance Level PLr
Structure (Category)
Diagnostic Coverage (DC)
Reliability (MTTF)
Balancing Structure (Cat), Reliability (MTTFd) and Diagnostic Coverage (Dcavg)
Copyright © 2016 Rockwell Automation, Inc. All rights reserved.
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Introduction to
SISTEMA & Safety
Automation Builder
Copyright © 2011
Rockwell Automation, Inc.
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Leverage SISTEMA for Real Time Validation
• SISTEMA – Safety Integrity Software Tool for the Evaluation
of Machine Applications
– SISTEMA provides a comprehensive method for evaluating ISO
13849-1 compliant Safety Control Circuits
– The tool enables you to model the structure of the safety-related control
components based upon the designated architectures.
– The tool offers automated calculation of a safety function’s attained PL
by using product data provided by safety product manufacturer.
– SISTEMA is a free software tool designed by Germany’s IFA (Institute
for Occupational Safety & Health).
SISTEMA simplifies the PL calculation of a safety function
Discover.RockwellAutomation.com
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SISTEMA TerminologyRelationship of 7 Hierarchical Levels in Sistema
INPUT LOGIC OUTPUT
- Project: Refers to machine or summary of safety functions
- Safety Function: Safety oriented response to an triggering event
-Subsystem: Group of Blocks within a defined structureInput - Logic - Output
-Channel: Connection of Blocks in series
-Test Channel: Confirms safety function channel is executing properly
-Block: Component in the function or test channel
-Element: Component reliability measure expressed as B10d value by vendor.Number of cycles until 10% of sample fail dangerously
“Safe operating stop
when a guard door
is opened”
Channel 1
Channel 2
Logic
Device
Safety Output
Contactor 1
Safety Output
Contactor 1
Switch channel 1
Switch channel 2
contactslinkage
contactslinkage
Sistema Project View
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SISTEMA RA Library View
Product Data
Library
Selection
Rockwell
Automation
Product Library
SISTEMA User Interface – Library View
Attribute Tabs
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Sistema Report View
Copyright © 2009 Rockwell Automation, Inc. All rights reserved.
Review the SISTEMA project
information to ensure that the
components, structure and design
meet the required Performance Level
SISTEMA Data created & exported
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SISTEMA… TUV Recommended
SISTEMA is the ONLY software tool recommended by TÜV!
– From TÜV Webinar in March 2009:
- Frank West
Senior Product Safety Service Engineer,
TÜV SUD
“We recommend [SISTEMA]. The important thing
to us as a third party assessor is that [SISTEMA] is
from a German governmental agency, so it’s not
attached to any particular vendor of components…
its neutrality is more reliable.
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Free Software Download
‘Safety Solutions’
To Access the
Safety Portal
www.machinesafetysolutions.com
Safety Automation Builder
No-charge Software tool to help design a Machine Safety System
Name, description, etc. here
Create a Project
Choose or Import Graphics
Machine Images
Answer Risk Assessment Question
Answer Safety Function Question
Answer Required PL Question
Select the default PL for the system
Risk Assessment Questions
Click the zone shape and drag it onto the image
Re-size & rotate
as needed
Define Functional / Safety Zones
Click the hazard tab to create a hazard
Click the type of hazard then select
& drag the icon onto the image then
re-size as needed
Define Functional / Safety Zones
Input selection box for choose a
product type
Click on the configure box to start
Raise
Select & Configure Devices
Copyright © Rockwell Automation, Inc. All rights reserved.32
Free Software Download
‘Safety Solutions’
To Access the
Safety Portal
www.machinesafetysolutions.com
Introducing…Common Safety Functions Library
• Examples for “safety relay” and “safety PLC” systems
• Breadth of examples including
• E-stop
• Light Curtains (Muting & Non-muting)
• Two hand control
• Enabling Switch
• Guard-locking switches
• Door interlocks
• Thorough documentation, wiring, programming, analysis, and more
Introducing…Common Safety Functions Library
Machine Safety Symposium
http://www.machinesafetysolutions.com
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