report nº 2704a35 · 2019-06-04 · 2 dme engineering - consulting - projects - management phone:...

REPORT nº 2704A35

CONFORMITY ASSESSMENT REPORT

SAFETY SYSTEM, ACCORDING TO NR 12

RUBBER INJECTOR MOD. REP RT9-250Y20-A

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DME Engineering - Consulting - Projects - Management

Phone: +55 11 4653-3124 / Cell Phone: +55 11 96734-2188

MANUFACTURER

Name:

Address:

CNPJ:

COMPANY REPRESENTATIVES

In response to a request from this reputed company, through its representatives Mr.

- Administration and Sales & Mr. - Coordination and Post Sales, we present the

appraisal report of the equipment in compliance with the provisions required by NR-

12 (Regulatory Norm Number 12 - Machinery and Equipment).

TECHNICAL REPRESENTATIVE FOR THE ELABORATION OF THE

REPORT

Responsible for preparing the report: Carlos Alberto de Oliveira Technologist in

Automation & Glauton Machado Barbosa, Mechanical Project Engineer.

TECHNICAL INFORMATION ABOUT THE ASSESSED EQUIPMENT

Device: Rubber Injector

Model: RT9-250Y20-A

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Phone: +55 11 4653-3124 / Cell Phone: +55 11 96734-2188

Summary

1 Normative References ................................................................................................. 4

2 Objectives and Methodology ...................................................................................... 4

3 Basic Summary ............................................................................................................ 4

3.1 Definitions ............................................................................................................... 5

3.1.1 Mechanical Protection Fixed ................................................................... 5

3.1.2 Mechanical Protection Mobile ................................................................ 5

3.1.3 Security sensors .......................................................................................... 6

3.1.4 Emergency Stop Device ............................................................................ 6

3.1.4.1 Suitable Signage ................................................................................. 6

3.1.4.2 Acting Right ........................................................................................ 6

3.1.5 Electrical Command .................................................................................. 7

4 Evaluation NR12 ........................................................................................................... 7

4.1 Drive System ........................................................................................................... 7

4.2 Machine Safety Monitoring .................................................................................... 9

4.3 Remote Actuator Monitoring ................................................................................ 11

4.4 Emergency Stop System ....................................................................................... 13

4.5 Manual Reset ........................................................................................................ 15

4.6 Electrical Panel / General Switch with Lockout for De-energization ................... 18

4.7 Operation Signaling .............................................................................................. 20

4.8 Electrical and Hydraulic Manuals / Diagrams ...................................................... 21

4.9 Pressurized Components ....................................................................................... 22

5 Responsibilities .......................................................................................................... 24

5.1 Elaboration ............................................................................................................ 24

5.2 Technical and Legal Responsible ......................................................................... 24

5.3 ART ....................................................................................................................... 25

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Phone: +55 11 4653-3124 / Cell Phone: +55 11 96734-2188

1 Normative References

ABNT NBR NM 272 - Machine safety - Protections - General requirements for the

design and construction of fixed and mobile guardsNBR 5410 - Electrical installations

of low voltage

NBR 5410 - Electrical installations of low voltage

NR10 - Facilities and Services in Electricity

NR12 - Safety in Machinery and Equipment

2 Objectives and Methodology

The purpose of this Technical Report is to evaluate compliance in compliance with

regulatory requirements, to verify the condition of safe operation, to inform about the

risks that the machine offers which are the prevention or protection measures that exist

to control the risks, which The chances of hazards being eliminated, and which parts of

the machine and equipment are subject to injury and damage. The methodology used for

this report was an analysis of the electrical diagram, hydraulic diagram, technical audit

visit was not performed on this machine model to verify the equipment in question to

prove the information, then a visit was made in a previous version to that one.

3 Basic Summary

The Technical Report on Conformity Assessment consists basically of the following

information:

• Short technical description of the machine;

• Indication of any non-conformities, marked in red, accompanied by solutions for

their sanitation, according to NR-12;

• Indication of any conformity, marked in green.

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Phone: +55 11 4653-3124 / Cell Phone: +55 11 96734-2188

Injection press mod. RT9-250Y20-A - Clasp type, vertical; Hydraulic drive; capacity

2450KN.

3.1 Definitions

SAFETY SYSTEMS (SAFETY PROTECTIONS OR SAFETY DEVICES OR

THEIR COMBINATION TO PREVENT ACCESS TO RISK OR DANGEROUS

MOVEMENTS) In accordance with items 12.38 to 12.55.1 - NR-12, General

Provisions.

3.1.1 Fixed Mechanical Protection (Fixed physical barrier, or fixed protection,

according to NR-12, item 12.38 - General Provisions).

It is the one fixed by screws which can only be removed with tools, and can not

be bolts of the butterfly type, rings or any other modality that allows their removal by

hand, according to ABNT NBR NM 272. The condition of fixed mechanical protection

is Only required in the operating cycle, but the other steps of use (maintenance

adjustment and etc.) require the complete stop of the movements to remove the

protection. For the application of the exception provided for by the NR-12, for the

maintenance stages, a documented justification, which is subject to evaluation and

reception or not, by the public worker's health and safety agent is required.

3.1.2 Mechanical Protection Mobile (Mobile physical barrier, or Mobile protection,

according to NR-12, item 12.38 - General Provisions).

It is one that allows movement during the normal operation cycle, but requires a

safety interlocking capability, according to ABNT NBR NM 273, or locking device,

according to the machine mode and mode of operation and according to the nature of

the risks (*).

(*) There are specific situations that require the simultaneous use of interlocking and

blocking.

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3.1.3 Security Sensors (According to NR-12 item 12.42, letter "c" - General

Provisions) Device that allows access and entry into the risk area, but ensures the

machine is stopped, preventing the reach of the risk area, under risk conditions. The

invasion of the hazardous area is detected and sends a signal to stop or prevent the onset

of dangerous movements or functions. (examples are: light curtains and other

optoelectronic presence detectors (AOPD), multi-beam laser, optical barriers, area

monitors, scanner devices, security mats and position sensors)

3.1.4 Emergency Stop Device (Conditions required for emergency button with

principles equally applicable to other emergency stop modes):

3.1.4.1 Appropriate Signaling

Emergency button (or other mode) is properly signaled when simultaneously

meeting the following conditions:

• Identification base of the word EMERGENCY, as a facilitating

recommendation for the identification, in yellow / black letter and in

Portuguese.

• Emergency button in red color, mushroom latch type, which can be triggered

without difficulty with the palm of the hand.

3.1.4.2 Appropriate performance

Emergency button displays proper performance when you simultaneously meet

the following conditions:

• It is a locking / mushroom type (tightening sinks, requiring the unlocking to

start operation);

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• Requires manual reset ( the emergency button unlocking can not enable the

machine to be triggered without the reset button being pressed;

• Ensures machine standstill, with prompt stop of all movements of the

monitored machine.

3.1.5 Electrical Command (Or Safety Interface, according to NR-12, treated by

Process Unit by Manufacturers) to monitor safety devices (so-called by the NR-12,

which are electronic actuators / optoelectronic / electromechanical Configure action at a

distance): According to item 12.42 letter "a" - NR-12 - General Provisions.

All remote actuators (pushbuttons, emergency buttons, restraints, light curtains,

interlocks, safety valves, others) must be monitored by a suitable process unit (Safety

Interface), which may be one of the Three modes: safety relay, safety PLC or Safety

CCS (configurable controller).

4 Rating NR 12

4.1 Drive System

• Injector hydraulic motor / pump drive is powered by an on / off (green-on / red-

off) system located on the front panel of the machine's electrical panel.

• Electrical circuit prevents start / restart of the cycle (on / off), before any stop

(emergency / interlock).

• Power button, is only reactivated with the mechanical activation of the emergency

(unlock) button.

• Off button, prevents any reactivation of the hydraulic pump motor.

• The start, stop and start components operate at extra low voltage.

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.

System Identification On / Off Hydraulic Pump

Electrical Diagram - Hydraulic Pump On / Off System

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Legal base

Condition required by Items 12.24 to 12.37 (Start, start and stop devices)

Injection press mod. RT9-250Y20 W-101/1 ODM6236 S1- Type of closure, vertical;

Hydraulic drive; Closing force 91.6KN.

4.2 Machine Safety Monitoring

The RT9-150Y10 Injector has safety monitoring on the front of the machine

through category 4 light curtain (PX31), with interlocking lock in category 4 SICK

safety relay, limit switches (LS3) and (LS4) All with interlocked interlocks in Category

4 emergency stop relay of the Schneider Electric brand.

CAT.4 - B50 Light Curtain

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Electrical Diagram - Light Curtain and Cat.4 Safety Relay

Electrical Diagram - Safety Stop Switches and Emergency Stop Relay Cat.4

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Legal base

Condition Required by items 12.38 to 12.55 of the general provisions and Annex VI of

NR-12.

4.3 Remote Actuator Monitoring

The equipment has a safety monitoring system consisting of a category 4 SICK

safety relay with Category 4 light curtain interlocking, Schneider Electric category 4

emergency stop relay with interlocking limit switches (Electromechanical) and dual

channel emergency button.

Emergency Relay / Emergency Stop Relay Cat.4

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Electrical Diagram - Emergency Stop Relay

Electrical Diagram - Safety Relay

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Legal base

Condition Required by items 12.38 to 12.55 of the general provisions and Annex VI

Of NR-12.

Injection press mod. RT9-250Y20-A - Clasp type, vertical; Hydraulic drive; capacity

2450KN.

• Monitoring of Distance Actuators

4.4 Emergency Stop System

The equipment has 3 (three) emergency button, double channel monitored by

safety interface (Emergency Stop Relay), however, it was possible to identify if

emergency button identification base meets the NR12 requirement in items 12.56 to

12.63.1, as a facilitating recommendation for identification.

Emergency Button - Front Panel Power

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Emergency Button - Front Panel Power

Legal base

Condition required by Items 12.56 to 12.63.1 (emergency stop devices) of the general

provisions and Annex VI of NR -12

Injection press mod. RT9-250Y20 W-101/1 ODM6236 S1 - Type of closure, vertical;


• Emergency Stop System

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Phone: +55 11 4653-3124 / Cell Phone: +55 11 96734-2188

RECOMMENDATION FOR CONDITION REQUIRED BY THE ITEMS 12.56 A

12.63.1 (emergency stop devices) of the general provisions and Annex VI of NR -12

• Replacement identification base in yellow / black letter and in

Portuguese, from the word EMERGENCY of Brazil, as a facilitating

recommendation for identification.

Emergency Button Plate

4.5 Manual Reset

The equipment has a reset button, however, it was possible to identify if it

meets the NR12 requirement in items 12.40 (safety system)

12.63 (emergency stop devices) of the NR-12 General Provisions.

Electrical Panel - Manual Reset Button

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Phone: +55 11 4653-3124 / Cell Phone: +55 11 96734-2188

Electrical Diagram - Reset Button Safety Relay

Electrical Diagram - Reset Button Emergency Stop Relay

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Phone: +55 11 4653-3124 / Cell Phone: +55 11 96734-2188

Legal base

Condition required by Item 12.40. (Safety system) and item 12.63 (emergency stop

devices) of the NR-12 General Provisions.



• Manual Reset

RECOMMENDATION FOR CONDITION REQUIRED BY ITEMS 12.40.

(Safety system) and 12.63 (emergency stop devices) of the General Provisions of NR-

12.

• Installation of manual reset button (blue reset), ie unlocking the

emergency button can not enable the machine to be triggered without the

reset button being pressed.

• Reset button, current on the light curtain safety relay and also on the

emergency stop / door release and emergency button.

• If the equipment has 2 or more doors with a safety key and you want to

know which door is open, you can set a category 1 limit switch only to

indicate which door has been opened.

Manual Reset Button

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Phone: +55 11 4653-3124 / Cell Phone: +55 11 96734-2188

4.6 Electrical Panel / General Switch with Lockout for De-energization

The electrical panel has a locking access door, there is no safety warning and

identification of the internal circuits.

Electric panel

Legal base

Condition required by Items 12.118 and 12.119. (Signaling) of the General Provisions

Of NR-12.



• Electrical Panel / General Switch with Lockout for De-energization

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Phone: +55 11 4653-3124 / Cell Phone: +55 11 96734-2188

RECOMMENDATION FOR CONDITION REQUIRED BY ITEMS 12.118 AND

12.119 (Signaling) of the General Provisions of NR-12.

• Placement of safety warning signs and identification of internal circuits.

• General key installation with lock.

Identification Cards

General Key with Lock

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Phone: +55 11 4653-3124 / Cell Phone: +55 11 96734-2188

4.7 Operation Signaling

Safety light signaling device to warn workers and others about the hazards they

are exposed to, operating and maintenance instructions and other information necessary

to ensure the physical integrity and health of workers.

Control Panel - Operation Signaling

Electric Diagram - Luminous Signaling Operation

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Phone: +55 11 4653-3124 / Cell Phone: +55 11 96734-2188

Legal base

Condition required by item 12.116 and 12.121 (Signaling) of NR - 12



• Operation Signaling

4.8 Electrical and Hydraulic Manuals / Diagrams

The equipment manuals / electrical and hydraulic diagrams must

be written in Portuguese - Brazil.

https://drive.google.com/file/d/1CeAlYPj6BLuR7xrewRE5wgtQEMXDYR7J/view?usp=sharing

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Phone: +55 11 4653-3124 / Cell Phone: +55 11 96734-2188

Legal base

Condition required by Items 12.125 to 12.128 (Manuals) of the general provisions of

NR - 12.



• Electrical and Hydraulic Manuals / Diagrams

4.9 Pressurized Components

Additional measures must be taken to protect hoses, pipes and other pressurized

components subject to possible mechanical impacts and other aggressive agents when

there is a risk.

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Phone: +55 11 4653-3124 / Cell Phone: +55 11 96734-2188

Legal base

Condition required by Items 12.77 to 12.84.1 (Pressurized Components) of the general

provisions of NR - 12.



• Pressurized Components

RECOMMENDATION FOR CONDITION REQUIRED BY ITEMS 12.77 TO

12.84.1 (Pressurized Components) of General Provisions of NR-12.

• Hose protection installation

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Phone: +55 11 4653-3124 / Cell Phone: +55 11 96734-2188

5 Responsibilities

5.1 Preparation

Eng.º Glauton Machado Barbosa

5.2 Technical and Legal Responsible

Glauton Machado Barbosa

CREA/SP- 5.061.417.587/D

Project engineer

Inspector of CREA-SP

Full Member of the AEAAR Culture Council

Arujá, may 08, 2018

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Phone: +55 11 4653-3124 / Cell Phone: +55 11 96734-2188

5.3 ART

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Phone: +55 11 4653-3124 / Cell Phone: +55 11 96734-2188

report nº 2704a35 · 2019-06-04 · 2 dme engineering - consulting - projects - management phone:...

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