Machinery Safety System Selection and Development

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Following a risk assessment identifying hazards to be mitigated, suitable methods of safeguarding measures to meet machinery safety standards must be designed and implemented. Safety automation technologies are usually deployed including inputs, logic device and outputs to perform a specific safety function. This session will cover safety function design, equipment selection for specific applications including on-machine and process machinery, including tools to expedite and document the process. We recommend attending SF01-Safety System Development Process and Configuration Tools Overview prior to this session.

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Machinery Safety System Selection and Development

  1. 1. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Machinery Safety System Selection & Development
  2. 2. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Agenda Types of Safety Logic Systems Safety Logic System Functionality and Purpose Introduction Market Segments Differences in Safety Logic Systems Determining the Best Safety System for You How Rockwell Automation can Help
  3. 3. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Session Purpose and Intent  This session is meant to outline the steps of selecting & developing machinery safety solutions.  Additional sessions (SF01, SF02, SF04 & SF05) break this process down in more detail.
  4. 4. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Agenda Types of Safety Logic Systems Safety Logic System Functionality and Purpose Introduction Market Segments Differences in Safety Logic Systems Determining the Best Safety System for You How Rockwell Automation can Help
  5. 5. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.  5 SENSOR CONTROL SYSTEM Connection systems Sensors [e.g. Interlock switch] LOGIC SOLVER ACTUATOR Logic Solver [e.g. Modular Relay] Logic Solver [e.g. Programmable Controller]Networks Actuators [e.g. Contactors] Distributed Inputs Distributed Outputs Actuators [e.g. Servos, Std. Drives] Rockwell Automation has the broadest portfolio of safety sensors, safety logic systems, and safety actuators in the market! Safety System Components
  6. 6. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Safety Logic Devices Safety Logic Devices SENSOR CONTROL SYSTEM LOGIC SOLVER ACTUATOR Safety Logic devices monitor the status of safety input devices, make decisions, and control the safety output devices.
  7. 7. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Monitoring Control Diagnostics Logic Functionality
  8. 8. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Agenda Types of Safety Logic Systems Safety Logic System Functionality and Purpose Introduction Market Segments Differences in Safety Logic Systems Determining the Best Safety System for You How Rockwell Automation can Help
  9. 9. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.  There are 3 safety logic architectures that can be used to provide safety control  Dedicated Relay  Modular Relay  Safety PLC or Controller Safety PLC & Safety Controllers Modular Relay Dedicated Relay Inputs OutputsBase Safety Logic Architectures
  10. 10. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation Scalable Safety Solutions Integration Continuum Offering solutions that fit your needs, not ours! Cost-effective Component Solutions Mid-Range Solutions Integrated Solutions Low High Simple connectivity Mechanical linked machine Stand alone machine Low cost Just enough control Multi-axis motion Increased controller capabilities Mix of mechanical and electrical controls Low engineering costs Coordinated multi-axis motion Robotic feeders Electronic line shafting Advanced connectivity Advanced information capabilities Components Integrated Architecture 1010
  11. 11. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Agenda Types of Safety Logic Systems Safety Logic System Functionality and Purpose Introduction Market Segments Differences in Safety Logic Systems Determining the Best Safety System for You How Rockwell Automation can Help
  12. 12. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Safety Market Segmentation 30% of respondents use contemporary/integrated safety solutions. Source: Control Design Magazine Survey, June 2009 30% • The largest market for safety products is with the low to mid range OEMs. 70% use hard-wired relay-based safety systems.
  13. 13. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Cutting & slicing Machines Shrink Wrappers Form Fill & Seal Machines Food & Beverage Bottle labeling Integrated Bottling Lines Safety Market Segmentation High end safetyLow end safety 30% of the market Low end safety relay market Mid-range safety 40% of the market 30% of the market Mid level safety relay & controller market High level safety controller market Palletizers & De-palletizers Case Packer Systems
  14. 14. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Agenda Types of Safety Logic Systems Safety Logic System Functionality and Purpose Introduction Market Segments Differences in Safety Logic Systems Determining the Best Safety System for You How Rockwell Automation can Help
  15. 15. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Low Complexity Safety Systems Cutting & slicing Machines Shrink Wrappers Low end safety Low end safety relay market 40% of the market Tend to use Micro controllers and simple safety relay solutions with 1 zone of control & little to no motion control: Simple safety input monitoring and power isolation Simple safety input monitoring and drive control Benefits: • Low cost • Simple installation • Just enough control for small applications • Easy diagnostics at the relay
  16. 16. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Mid-level Complexity Safety Systems Require more than stand alone control but need low cost solutions. These systems typically have 25 to 100 points of I/O, 2 to 3 zones of safety control, 2 to 6 axes of motion control, and 2-6 screens of visualization. Modular and expandable relay systems that are capable of multiple zones of control Form Fill & Seal Machines Mid-range safety 30% of the market Mid-level safety relay & controller market Palletizers & De-palletizers Case Packer Systems Safety Controllers that have network and zone control capability Benefits: • Low to medium cost • Simple installation • Just enough control for the application • Easy diagnostics at the relay and HMI • Expandable • Networkable • Can do some zone control
  17. 17. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. High Complexity Safety Systems Food & Beverage Bottle labeling Integrated Bottling Lines High end safety 30% of the market High level safety controller market Solutions in the high end market tend to be solutions that are large, complex and integrated. These systems often have multiple zones of control, distributed I/O, multiple axis of motion control, high I/O counts and complex safety needs. Benefits: • Scalable • Networkable • Modular • Easy diagnostics via communications to a common HMI screen. • Expandable • Flexible • Productivity Gains • Efficiency Gains
  18. 18. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Shared assets across standard & safety control drive cost savings and add significant value throughout the manufacturing process. High End Safety Systems are also known as Integrated & Contemporary Safety Systems!
  19. 19. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.9/9/2011 The New Standards Allow the Use of Contemporary Safety Solutions that Provide Better Solutions for Customer Needs! We use the term contemporary because it is a change in the way safety systems have been applied & integrated in the past. Safety was an add-on to the control system. Contemporary safety solutions are embedded into the design thus becoming a part of how the machine operates. Examples of contemporary solutions are described below:  Safe speed – This allows for minor machine servicing like adjustments, feeding, cleaning & wash-downs without shutting the machine down because the machine is operating at a speed that deemed to be safe (Less than 250mm per second).  Safe direction – This allows for cleaning & adjustments because the hazard has been removed by reversing hazard causing motion.  Safe position – This allows for interaction with equipment as long as the hazard is in a safe position/location.  Zone control – This allows for parts of a machine to operate while other pieces to continue operation thus reducing scrap & waste.  Advanced diagnostics – Contemporary safety solutions typically have better diagnostics because the standard and safety control are in 1 control system. This allows for better MTTR (Mean Time To Repair).  Distributed I/O – (Both safety and standard). This allows for modular designs that can be broken down for quick shipping and re-assembly at customer locations.
  20. 20. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Contemporary Safety Brings Things Together! ControlLogix chassis PowerFlex 755 Armor Block I/O EtherNet/IP PV+ EOI Safety Relay Safety Relay Stratix 8000 E T A P POINT I/O Safety System An ethernet switch may not be required. Safety functionality can now be integrated into GuardLogix. Data & diagnostics can be displayed on one HMI. Benefits Information enabled. Fewer components. Less training. Streamlined maintenance. Optimal connectivity with multiple networks. Kinetix 6000 DeviceNet Safety relays & contactors may not be required.
  21. 21. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Communication & Coordination Logic Standard Controller Motion Controller Safety Controller Software Logic Integrated Safety Controller Control Integrated safety solutions reduce engineering and design times by 20 to 30%! Integrated safety solutions reduce trouble-shooting times by 25% Integrated safety solutions improve productivity by 3 - 5 % (1% productivity = $250K - $2M) Competitive vs. Rockwell Automation Solutions Software Logic
  22. 22. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Agenda Types of Safety Logic Systems Safety Logic System Functionality and Purpose Introduction Market Segments Differences in Safety Logic Systems Determining the Best Safety System for You How Rockwell Automation can Help
  23. 23. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 23 How Do I Determine the Best Safety System for Me?
  24. 24. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Follow the Safety Life Cycle! 5. Operate, Maintain and Improve 1. Assessment 4. Installation and Validation 2. Functional Safety System Requirements 3. Design and Verification Identifies Task & Hazards Pairs Circuit & Component Selection Safety System Design Design Verification Guarding design Outlines functional requirements of the safety system Final site assembly Commissioning Validation Final Assessment Validation Detailed operational specification Required maintenance schedule Preventive maintenance schedule The Safety Life Cycle Helps You Determine System Requirements & Needs! Steps 1 & 2 help to define system requirements prior to the selection & design process!
  25. 25. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Step 1: Do a Risk Assessment!  ISO-13849-1 identifies a risk assessment as the means of determining risk levels, associated risk reduction methodologies, and the type of safety system performance that needs to be implemented.  Risk assessments also help identify each hazard that needs to be safeguarded. S1 S2 F2 F1 a b P1 P2 e c d P1 P2 P1 P2 P1 P2 F2 F1 b c d
  26. 26. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Step 2: Develop a Functional Specification!  A Functional Safety Specification helps determine the proper safety function needed to protect people from each hazard on the machine/system.  Functional specifications determine the following:  Safety system needs for each mode of operation.  Safety function(s) needed to mitigate each hazard/risk.  Safety system structure & technologies (Zones/Safe Speed/Safe Direction).
  27. 27. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. My assessment & requirements spec sure made this easy! Step 3: Design & Selection Considerations! 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?
  28. 28. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Additional Factors in Determination of Design  Category, PL, or SIL level requirement  Functional requirements  Compatible interfaces to sensors and actuators  System size / footprint  System complexity – Logic Requirements  Process complexity  Zoning requirements  Safety Monitoring / Diagnostics / Information  Documentation, Validation, Reporting  Cost
  29. 29. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Cultural Factors that Drive Relay and Controller Selection! 1. Customer does not use automation products 2. Customer’s Maintenance staff does not use PCs and is not software literate 3. Customer not clear on how safety systems will impact his business, plant, machinery, or processes 4. Customer very happy with SLCs, Micrologix or similar low end PLC solutions 1. Customer is a sophisticated user of automation 2. Customer Uses Integrated Architecture / Logix 3. Customer has challenging applications and can deal with overhead to “get started” 4. Customer has numerous potential applications and wants to maximize productivity Safety Relay Solutions Integrated Safety Controller Solutions
  30. 30. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Compact GuardLogix Safety Control System Options (Control Devices) 30 FlexibilityandPrice Safety System Complexity / Functionality MSR Relay SmartGuard 600 GuardLogix Armor GuardLogix CR30 GSR Relay GSR & MSR Safety Relays  Cover most safety functions  Modular expansion  Configurable Guardmaster® CR30 • Software Configurable Safety Relay • Supports up to 10 safety input circuits and up to 5 safety output zones • 22 Safety I/O; expandable by up to 16 standard I/O • One software supports Guardmaster CR30, Micro800®, PowerFlex®, and PanelView™ Component SmartGuard™ 600  Dedicated safety controller with EtherNet/IP connectivity  16 safety inputs / 8 safety outputs / 4 std outputs  Networked safety I/O expansion (CIP Safety on DeviceNet) Compact GuardLogix  High performance integrated safety  Standard , Safety, and Motion control  CIP Safety on EtherNet/IP  Superior ease-of-use for SIL2, SIL3, PLe safety functions  High Integrity AOIs GuardLogix  High performance integrated safety  Standard , Safety, and Motion control  CIP Safety on DeviceNet, ControlNet, Ethernet  Superior ease-of-use for SIL2, SIL3, PLe safety functions  High Integrity AOIs Armor GuardLogix  Full capabilities of GuardLogix  SIL3, PLe, CAT 4 safety control  IP67 wash-down protection  2 independent dual EtherNet/IP ports w/ DLR support  24VDC pass-through power
  31. 31. Copyright © 2014 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 / Configurable Relays • 1 to 3 Zones • Local & Distributed I/O • Simple & Semi-complex Safety Logic • 1 to 10 dual channel Inputs • 1 to 10 outputs • Basic Diagnostics thru PLC Safety PLCs • More Than 3 Zones • Distributed I/O • Simple & Complex Safety & Standard Logic • 1 to 200 dual channel Inputs • 1 to 200 outputs • Advanced HMI Diagnostics
  32. 32. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Agenda Types of Safety Logic Systems Safety Logic System Functionality and Purpose Introduction Market Segments Differences in Safety Logic Systems Determining the Best Safety System for You How Rockwell Automation can Help
  33. 33. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation Service & Support!  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 Resources Over 200 Training Courses for help customers develop competency 30 + RA Safety Professionals 3 RA Safety Partners – 20 Resources 4 Safety Professionals 20+ RA Safety Professionals 12 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!
  34. 34. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation has Safety Tools to Help Customers be Compliant and Safe! 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 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. 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. 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 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 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. The broadest suite of safety tools in the industry!
  35. 35. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. We care what you think!  On the mobile app: 1. Locate session using Schedule or Agenda Builder 2. Click on the thumbs up icon on the lower right corner of the session detail 3. Complete survey 4. Click the Submit Form button 35 Please take a couple minutes to complete a quick session survey to tell us how we’re doing. 2 3 4 1 Thank you!!
  36. 36. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Questions?
  37. 37. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Thank you for participating!

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