Safety System Development Process and Tools Overview

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  • 1. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900DSafety System Development Process &Configuration Tools Overview.Chris Brogli – Global Business Development Manager for Safety
  • 2. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Session Purpose and Intent This session is meant to outline the steps of developingmachinery safety solutions and tools that can help reducethe time to develop, implement and start up a machinerysafety system. Additional sessions (SF02, SF03, SF04 & SF05) breakthis process down in more detail.
  • 3. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. 3AgendaClosing & Wrap-upSample Project Utilizing the toolsSelection, Design, Verification, Development &Justification ToolsSafety Life-cycle UtilizationSafety System Development Process
  • 4. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Safety System Development Process4 Common Safety SystemDevelopment Process Machine review & hazardidentification Product Selection Safety System Design Safety System Installation Start Production Proper Safety SystemDevelopment Process Risk Assessment Functional SpecificationDevelopment Product Selection Structure Selection Design Design Verification Installation Verification & Validation Training Operation & Maintenance
  • 5. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Most people use the common approach! 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 safetydevices/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 significantreductions in equipment utilization!5Most people have never been to a training session or have never read amachinery safety standard! This results in safety systems that areinadequate, ineffective & improperly designed.
  • 6. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.The Proper Approach: A standardsbased methodology!6 Both EN, ISO and ANSI standards require a systematic approach for safetysystem development! So which standard is right for you?S1S2E1E2R1A1A2A1A2A1A2A1E1E2R2AR2BR2BR2CR3AR3BR4S1S2F2F1abbP1P2eccddP1P2P1P2P1P2F2F1bbccddORANSI/RIA Method EN/ISO MethodEither is OK but the move is towards the ISO method because of new tools!
  • 7. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Development Considerations! What machine/machines are to be guarded? What are the characteristics and limits of themachine/machines? What are the different modes of operation ofthe machine/machines? Who interacts with these machines duringnormal and abnormal operation? What are those people doing? How does the machine need to function ineach 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 themachine/machines? What is the company specification? What can be done to improve safety andproductivity?What do I need to consider?
  • 8. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. 8AgendaClosing & Wrap-upSample Project Utilizing the toolsSelection, Design, Verification, Development &Justification ToolsSafety Life-cycle UtilizationSafety System Development Process
  • 9. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.The Rockwell Automation approachfollows the “Safety Life Cycle”91. AssessmentThe Machinery Safety Lifecycle is a defined process that is followedto ensure that proper safety practices have been implemented!5. Operate, Maintain& Improve4. Installation& Validation 2. FunctionalRequirements3. Selection, Design & Verification
  • 10. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation follows the safety lifecycle toevaluate machinery safety solutions because: It remove uncertainty and eliminates omissions and errors! It provide a repeatable process that leads to complete safety solutionsAn idea without a plan leads to indecision, omissions and mistakes!Rockwell Automation Safety Lifecycle
  • 11. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 11Step 1 in the Machinery Safety Lifecycleis the Assessment!5. Operate, Maintain& Improve1. Assessment4. Installation& Validation 2. FunctionalRequirements3. Selection, Design & VerificationProper safety system development starts here!
  • 12. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.What is anassessment andhow do I do it?Step 1: The assessment. The foundationof safety system development!Machine Characteristics/LimitsRisk EvaluationHazard IdentificationRisk EstimationRisk ReductionRiskTolerableOKToo HighRisk Assessment Processaccording to ISO12100
  • 13. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation utilizes 3 types ofassessments!SafetyServiceHazard / GuardingAssessmentSafety Assessment / Audit Team-Based Risk AssessmentIdentifies Primary Hazards Assessment & Estimate Detailed Risk AssessmentPurpose Identifies guarding/ hazards forimmediate plant actionsMost common – provides report & estimates todevelop safety plansIn-depth analysis required for critical or specialmachinesServiceDeliverables One Page Reportidentifying hazards and“Risk-in” rating only Does not include: Risk Out rating Cost estimation Pictures Assessment led by RA Consultant, limitedcustomer involvement Report per standard Identification of primary hazards/tasks List non-compliance issues Risk In / Risk Out Rating Mitigation Guarding and Controlsrecommendations Prioritized recommendations for safetyimprovements Photograph of critical identified hazards(based on customer approval) Cost estimate per machine Team-based assessment led by RAConsultant for all machine life phases Report per standards Identification of primary hazards/tasks List non-compliance issues Risk In / Risk Out Rating Mitigation Guarding and Controlsrecommendations Prioritized recommendations for safetyimprovements Photograph of critical identified hazards(based on customer approval) Cost estimate per machine Mitigation Drawing Includes ergonomics review (slip, trip, andfall hazards)XXScalable assessment solutions to meet any need!
  • 14. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 145. Operate, Maintain& Improve1. Assessment4. Installation& Validation 2. FunctionalRequirements3. Selection, Design & VerificationStep 2 in the Machinery Safety Lifecycleis the safety requirements specification!The SRS defines the functional requirements of the safety system!
  • 15. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.The main reason for developing afunctional spec!The SRS defines my solution! It identifies how the machine is to operate in each mode ofoperation 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
  • 16. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 165. Operate, Maintain& Improve1. Assessment4. Installation& Validation 2. FunctionalRequirements3. Selection, Design & VerificationStep 3 is the selection, design & designverification phase.This step focuses on safety system design, product selection,circuit selection and design verification!
  • 17. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.My assessment &requirements specsure made this easy!The design phase includes selection ofmitigation 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 forauxiliary machines? What kind of diagnostics do I need? Should I use hardwiring or networkedsystems?Step 3 is the selection, design & designverification phase.
  • 18. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2007 Rockwell Automation, Inc. All rights reserved.18Possible Mitigation Techniques!Design it outFixed enclosing guardMonitoring Access /Interlocked GatesAwareness Means, Training andProcedures (Administrative)Personal protective equipmentMostEffectiveLeastEffectiveHierarchy of Protective Measures
  • 19. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Copyright © Rockwell Automation, Inc. All rights reserved.19Types of Categories (Structures)CAT B/1 CAT 2CAT 3 CAT 4 (higher diagnostic coverage that CAT 3)
  • 20. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Product Selection Options! The risk assessment tool identified the required performance level andCategory that is required for each part/portion of the machine. Useproducts that meet the required performance level (PLr) and/or theCategory 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 devicesRemember your weakest link sets your maximumsystem performance that can be achieved!
  • 21. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Select devices to make completesolutions!SafetyControllersRelaysSystemsSafetyPLCsVFD’sContactorsServo’sInput Logic Output
  • 22. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Safety Relay/Safety Controller/SafetyPLC Selection Matrix!Safety Relays 1 Zone Local/Hardwired I/O Simple Safety Logic 1 to 2 dual channel Inputs 2 to 3 outputsSafety Controllers & ExpandableRelays 1 to 3 Zones Local & Distributed I/O Simple & Complex SafetyLogic 1 to 20 dual channel Inputs 1 to 20 outputs Basic Diagnostics thru PLCSafety 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
  • 23. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Safety Output Selection!Safety Contactors & Relays Simple on/off control Power control Signal controlSafety Variable Frequency Drives On/off control with the abilityto control & monitor speedSafety Servo Systems On/off control Speed control Direction control Position control Location control Acceleration control Decceleration control
  • 24. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Scalable Safety SolutionsIntegration ContinuumOffering solution that fit your needs, not ours!Cost-effective Component Solutions Mid-Range Solutions Integrated SolutionsLow HighSimple connectivityMechanical linked machineStand alone machineLow costJust enough controlMulti-axis motionIncreased controller capabilitiesMix of mechanical and electrical controlsLow engineering costsCoordinated multi-axis motionRobotic feedersElectronic line shaftingAdvanced connectivityAdvanced information capabilitiesComponents & Intelligent Motor Control Integrated Architecture™2424Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
  • 25. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.How do I verifymy design!The design phase also includes designverification! 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?
  • 26. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Design Verification Methods –Option 1 - Calculation Method26MTTFd Mean Time to Dangerous FailureLow 0 -10 YearsMedium 10-30 YearsHigh 30-100 YearsDC Diagnostic Coverage = Detected Dangerous Failures / All Dangerous FailuresNone DC < 60%Low 60 < DC < 90%Medium 90 < DC < 99%High DC >99%
  • 27. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.27abcdePerformanceLevelDesignatedArchitectureDesignatedArchitectureDesignatedArchitectureDesignatedArchitectureDesignatedArchitectureDesignatedArchitectureDesignatedArchitectureCat B Cat 1 Cat 2 Cat 2 Cat 3 Cat3 Cat 4DC 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 PLr is achieved by…Balancing Structure (Cat), Reliability (MTTFd)and Diagnostic Coverage (DCavg)
  • 28. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Design Verification Methods –Option 2 - SISTEMA Method28SISTEMA is a free design verification tool that isinternationally recognized!
  • 29. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Design Verification Methods –Option 3 – SAB & SISTEMA Method29SAB utilizes SISTEMA for design verification but simplies theprocess by using menus and questions!
  • 30. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 305. Operate, Maintain& Improve1. Assessment4. Installation& Validation 2. FunctionalRequirements3. Selection, Design & VerificationStep 4 ensures that the system was installedproperly and that the system functions as intended!This step focuses on ensuring that the safety system was installated properlyand that there is a defined process for validating system performance!
  • 31. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.How do I installmy safetysystem?Step 4 - Installation Installation considerations: There should be specific instructionsregarding physical barrier installation! There should be specific instructionsregarding safety product installation andwiring! There should be specific instructionsregarding wiring methods and grounding! There should be specific instructionsregarding panel fabrication and wiring! There should be specific instructionsregarding signage installation and location! There should be specific layout drawingsshowing a routing, mounting and installationinstructions! There should be specific electricalschematics regarding terminations &connections.
  • 32. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.How do I validate mysafety system? Validation considerations: There should be specific instructionsregarding the validation of for each safetyfunction! This means that each safety input, logic &output device must be tested to ensure itfunctions as intended! This means that each combined functionof input/logic/output must be tested toensure that it functions as intended! This means that each programmedfunction is validated to ensure it functionsas intended! There should also be specific instructionsregarding fault injection to test the safety ! Common testing methods include: Shorting wires, breakingconnections, removing wires, etc.Step 4 Continued - Validation
  • 33. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 335. Operate, Maintain& Improve1. Assessment4. Installation& Validation 2. FunctionalRequirements3. Selection, Design & VerificationStep 5: Operate, maintain and improve ensures that thesystem is operated properly and that the system is maintainedto ensure continued effectiveness!Step 5 focuses on ensuring that the safety system is operatedproperly and maintained to ensure continued effectiveness!
  • 34. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.How do I operate mymachine?Step 5 – Operate, Maintain & Improve The should be training for all personnel thatwill be interacting with the machine. The training should include: Intended use Safety system components training Normal operations Safety system operations
  • 35. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.How do I maintain mysafety system?Step 5 – Operate, Maintain & Improve The standards say that periodic testingshould be done to verify proper systemfunctionality. (There is no defined period ortimeline that is suggested) The standards also require additionalassessments after machine modifications.This might include: Program changes Safety system use Hardware changes Machinery changes System modifications
  • 36. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 365. Operate, Maintain& Improve1. Assessment4. Installation& Validation 2. FunctionalRequirements3. Selection, Design & VerificationThe Machinery Safety Lifecycle Never Ends!The circle never ends. The system must be re-evaluatedanytime modifications occur and each step must be followed!
  • 37. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. 37AgendaClosing & Wrap-upSample Project Utilizing the toolsSelection, Design, Verification, Development& Justification ToolsSafety Life-cycle UtilizationSafety System Development Process
  • 38. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.How do we rank against competitors?Rockwell Automation moved into the number 1 provider ofsafety solutions because of investment in products,services & tools that help customers maximizeperformance!
  • 39. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation investmentin technologies! Integrated Safety Platforms Safety Instructions & Applications Functional Safety Compliance Embedded Safety Capabilities Advanced Safe Motion Functions Integrating Control, Safety & Motion CIP Safety for DeviceNet & EtherNet/IP Low Cost Safety Networks Dual Port EtherNet/IPThe broadest portfolio of safety products in the industry!
  • 40. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation investment inServices! Assessments Arc Flash Analysis Hazard Risk LOTO HAZOP Validation Safety circuitanalysis Machine stop timeservices Conformanceaudits Safety systemvalidation ComplianceConsulting CE conformance Functional safety(ex. ISO 13849-1and IEC 62061,ISO, ANSI, IEC, CE,OSHA, NFPA, CSA,AS )200+ Safety Professionals Available Globally100+ Machinery Safety Certified Resources80+ Process Safety ResourcesOver 200 Training Courses for help customers develop competency30 + RA Safety Professionals3 RA Safety Partners – 20 Resources4 SafetyProfessionals20+ RA Safety Professionals12 RA Safety Partners – 24+ Resources20+ Safety Professionals6 SafetyProfessionals5 SafetyProfessionals5 SafetyProfessionals Training TUV Certification Risk Assessments Safety Standards Safety Products Arc Flash LOTO Integration / Start Up Circuit/logic design Installation Arc flashremediation MCC Arc Flashupgrades ProjectManagement RemediationSolutions CompleteTurnkeySystemsThe most complete suite of safety services in the industry!
  • 41. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation’s investment intools!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 safetyapplications.SafetyFunctionsSafety Functions ProgramThe Safety Functions Program is building block approach to designing safety systems. Each building block has a completedocumentation package that includes a description of each safety function, an electrical schematic, a bill of material, aSISTEMA 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 identifyhazardous access points and the associated hazards in order to develop a list of safety products that will be used to mitigatethe risk. This gives the customer a complete drawing, a bill of material and SISTEMA calculation.SafetyAcceleratorToolkitSafety Accelerator ToolkitThis toolkit provides easy to use system design, programming, and diagnostic tools to assist you in the rapid development anddeployment of your safety systems using GuardLogix, Compact GuardLogix, or SmartGuard 600 Controllers, Guard I/O, andSafety 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.ConnectedComponentsBBConnected 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 theProSafeBuilderProSafe BuilderThe ProSafe Builder software gives users the ability to layout complete trapped key solutions for machinery safetyapplications with a tool that generate a bill of material and system configuration schematic/map.The broadest suite of safety tools in the industry!
  • 42. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Safety System Development Tools42SABSafety Automation BuilderThe Safety Automation Builder software package that allows users to import images of their machines. Users can identifyhazardous access points and the associated hazards in order to develop a list of safety products that will be used to mitigatethe risk. This gives the customer a complete drawing, a bill of material and SISTEMA calculation.ProSafeBuilderProSafe BuilderThe ProSafe Builder software gives users the ability to layout complete trapped key solutions for machinery safetyapplications with a tool that generate a bill of material and system configuration schematic/map.
  • 43. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.What is Safety Automation Builder (SAB)?SAB is a new tool designed to help develop complete safetysystem solutions. These solutions include conceptual layoutdrawings that includes zones, physical guards, hazards,access points and the products used to protect personnel.
  • 44. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.SAB ContinuedRisk Assessment Design VerificationDetermines (PLr) Confirms PLr Achieved
  • 45. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Qty Catalog Number Description DS List Ea Typical Delivery1 445L‐P4E0600FPMicro 400 Safety Light Curtain, Pair, Res 30mm, Pt Ht 600mm E8 $  1,220.00  Preferred2 445L‐AC8RJ5 M12 to RJ45, 5 meter E8 $        26.30  Preferred1 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  Preferred1 440R‐D22R2Guardmaster Safety Relay, 2 Dual Channel Universal Inputs, 1 N.C. Solid State Auxiliary Outputs E8 $     402.99  Preferred1 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  PreferredSAB – The Complete Safety SystemDesign & Verification Tool w/BOMComplete Safety System LayoutPerformance LevelVerificationComplete Bill of Material
  • 46. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.ProSafe Builder - Trapped KeyConfiguration Software The software will allowusers to layout trappedkey systems in asystematic method thatshows a flow view ofconfigured and selectedproducts.4The comprehensive trapped/captive key tool on the market!
  • 47. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Safety System InvestmentJustification Tool47Safety Return-On-Investment ToolFind out how to quantify the savings and productivity gainsfrom safety investments. The Rockwell Automation SafetyReturn-On-Investment Tool accounts for improved safety,reduced claims, improved productivity, and other issues uniqueto safety applications.
  • 48. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Justification Of Safety Investments 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 findingE. Perform an ROI48Answer: “E”Good News! Rockwell Automation Can Help With A Safety ROI Calculator“But how do I calculate a Safety ROI?”
  • 49. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.What is the Safety ROI Calculator Tool?49The industries only return on investment tool for safety projects!
  • 50. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.ROI Example Output!50The Safety ROI tools helps customers justify safety projects based onproject cost and injury avoidance calculations!
  • 51. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Safety System Design Tools51SafetyFunctionsSafety Functions ProgramThe Safety Functions Program is building block approach to designing safetysystems. Each building block has a complete documentation package thatincludes a description of each safety function, an electrical schematic, a bill ofmaterial, a SISTEMA verification calculation and a verification and validation plan.SafetyAcceleratorToolkitSafety Accelerator ToolkitThis toolkit provides easy to use system design, programming, and diagnostic toolsto assist you in the rapid development and deployment of your safety systems usingGuardLogix, Compact GuardLogix, or SmartGuard 600 Controllers, Guard I/O, andSafety Devices. The toolkit includes a risk assessment and system design guide,hardware selection guide, CAD drawings, safety logic routines, and operator statusand diagnostic faceplates.ConnectedComponentsBBConnected Components Building BlocksThese building blocks are tools that help customers develop safety solutions thatutilize component class safety solutions. These building blocks include sampleprograms, electrical schematics and configuration document that help in the
  • 52. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.5252SafetyLife Cycle5. Maintainand Improve1. Hazard or RiskAssessment4. Installationand Validation2. Functional SafetySystem Requirements3. Design and VerificationIdentify Hazards &estimate theassociated riskSystem ArchitectureSafety critical circuit designGuarding designValidation protocolBased on:- Risk Assessment- system performance- applicable s standardsFinal site assemblyCommissioning/ValidationTrainingFinal Risk Assessment ValidationVerify that system requirementsoperate within specified parameterfor Production and SafetyPreventative maintenanceand system upgradesSafety Functions help customers move beyond therisk assessment with complete Rockwell solutions!
  • 53. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Safety Functions are the building blocksof machinery safety solutions!Risk Assessment Model & Confirm PLrDetermines (PLr) Confirms PLr AchievedTo Realization and PL evaluation
  • 54. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.The more complicated the machine themores safety functions you need!E-Stop Device 1E-Stop Device 2Light Curtain 1Door Interlock 1LogicOutput 1Output 2Output 3SF1SF2LogicSF3SF4 Output 4LogicLogicLarge and complex machines may require multiple safety functions toprovide a complete machine safety solution. Safety function documents are1 way that Rockwell Automation can help!
  • 55. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. Safety Functions include GSR relay solutions andGuardLogix solutions. The initial 6 Safety Functions launched October 1st. Two additional ones launched in February. 13 additional Safety Functions will be added by the end of2013! Each safety function includes a functional specification, aelectrical diagram, a program or configuration document, aSISTEMA verification report and a verification & validationdocument to help users develop safety solutions quickly,easily and accurately with minimal effort.Introducing…The Safety Functions Library
  • 56. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. 56Sample Safety FunctionSafety Function: Emergency StopProducts: 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
  • 57. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.IA Safety Accelerator ToolkitDevelopment Tools and Quick StartGuideSimplified WiringPreconfigured LogicQuick Start ManualPreconfigured HMI
  • 58. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.IA Safety Accelerator ToolkitSafety Application Examples58Example CodeI/O ConfigurationDiagnostics
  • 59. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Instruction Faceplates Want to troubleshoot safetyinstructions from your HMI? NOW YOU CAN Display the instruction as theFunction it is performing. Estop Light Curtain Light Curtain Muting Etc.5959
  • 60. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Safety Accelerator ToolkitGuard I/O Status and Diagnostic Faceplates
  • 61. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Safety Performance Tools forGuardLogix® TUV Recognized Analysis Tools Single Channel Safety Reaction Time Tool Network Reaction Time Tool
  • 62. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.GuardLogix Safety Estimator Safety Tool to help estimate system performance and network configuration.
  • 63. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Connected Component Building Blocks for Safety63Pre-designed Building Blocks with source code, drawings and quick-startguide to help you develop safety solutions!
  • 64. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Implementation & Documentation Okay Here’s What We Accomplished So Far… Identified the Hazards and Documented Our Risk Assessment Developed the functional specification to Mitigate the Risks Designed the Safety Solution & Selected Components Verified the design to confirm the achievement of the required systemperformance. Performed an ROI analysis demonstrating the value of the safety system Leveraged example code, faceplates, wiring diagrams etc.64Complete documentation for your safety solution!
  • 65. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. 65AgendaClosing & Wrap-upSample Project Utilizing the toolsSelection, Design, Verification, Development &Justification ToolsSafety Life-cycle UtilizationSafety System Development Process
  • 66. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.The Safety Process – What do I do? 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?66Let’s Look At A Couple Of Options…
  • 67. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Let’s look at a sample machine! We are going to use the safety tools to develop a safety solutionutilizing Safety Automation Builder. This will leave us with a conceptdrawing, 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 safetyfunctions, safety accelerator toolkit and connected components buildingblocks.67
  • 68. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Machine Description68Infeed ConveyorOutfeedConveyorRotaryTableLabelP&PLabelFeederHot Glue GunProduct
  • 69. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Step 1 – Risk Assessment We are going to develop a risk assessment utilizing the ISO12100evaluation method.69S1S2F2F1abbP1P2eccddP1P2P1P2P1P2F2F1bbccdd
  • 70. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Step 1 Details Normal operation Maintenance Set-up Adjustment Change-over Start-up Decommissioning Etc.70Identify the hazards and associated risks! Develop a functionalspecification that outlines how each hazard needs to be protected foreach mode of operation.Thermal HazardCrushing HazardPinching HazardPinching HazardIt is estimated that 60 to 70% of all injuries happen outside of normal production activitiesyet most people spend 90% of their efforts around designing for production activities!
  • 71. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. 71Show how the ISO12100 risk methodology isused to determine the required systemperformance that is to be implemented.
  • 72. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Step 2: Write a Functional Specification The assessment defined the task and associated hazards and the requiredsystem performance that is required. The function specification will determine the required safety functions, theirdesign requirements and the type of functionality that is needed for eachmode of operation for each person that interacts with the machine.72
  • 73. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Next Step Define Our Safety Functions When Door Opens in zone #1, traypacking stops, zone #2, tray formingcontinues. Safety Function: Safety related stop functioninitiated by a safe guard Stopping hazardous movement Triggering Event: Opening of guard doorZone #1 Zone #2Follow This Process for Every Safety Function in Every Machine Mode!
  • 74. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. 74Show how to develop a functional specification.
  • 75. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Step 3: Develop a safety project utilizingSafety Automation Builder.75This screen shot shows the layout drawing with identified hazard locationsand access points that need to be protected!
  • 76. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Step 3: Users can now start the safetyselection process76This screen shot shows the layout drawings with the selected safety devices!
  • 77. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Step 3: Users can view the selected safetydevices for each access point by clickingon the table view!77This screen shot shows the devices that were selected for each safetyfunction!
  • 78. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Users can verify their design78This screen shot shows the safety design verification report from SISTEMA!
  • 79. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Completed Bill of Material fromProposalWorks &SAB!79This screen shot shows the completed bill of material for the labelermachine safety system!
  • 80. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. 80Show how to develop a SAB project.
  • 81. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Now we have a price! We need to justifythe investment!81 We will use the Safety Return on Investment Tool to justify the projectbased on projected reductions of injuries and productivity enhancements!Let’s calculate our savings and ROI for this machine example!
  • 82. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. 82Show how to develop a justificationreport using the ROI calculator!
  • 83. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.The next step after selection, designverification & justification is design!83Now we need to start making schematics, developing programs andconfiguration documents. We will guide you to locations that can help!The Safety Functions documents are found on the safety resource center!
  • 84. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Let’s search for the applicable safety functions!84
  • 85. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.An additional tool that can help is SafetyAccelerator Toolkit85Safety Accelerator ToolkitThe Safety Accelerator Toolkit can be found on the safety resource center orby asking your local Rockwell distributor!
  • 86. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Let’s search for the applicable safety accelerators!86
  • 87. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Connected Component Building Blocksfor Safety87The Safety Building Blocks can be found by asking your local Rockwelldistributor for a CD!
  • 88. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Let’s search for the applicablesafety building blocks!88
  • 89. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900DSummary
  • 90. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation the global leader insafety (Services/Products/Solutions)!Best in class assessment services to help you to determinesafety system needs!Safety Design Tools and resources to help engineers anddesigners with safety system development.Products selection and design verification tools to helpsengineers select product quickly and accurately.Installation and start-up services to help meet productivity andstart-up needs.Validation services to ensure that the safety system operatesas designed and constructed.Preventive maintenance development services to ensure thesafety system continues to operate properly.
  • 91. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900DQuestions?