Machinery Safety. TÜV SÜD.pdf

TÜV SÜD Product Service
Machinery Safety
Presented by Paul Laidler

Machinery Division Safety Solutions
• Assistance in meeting the requirements of
machinery safety legislation
– Machinery, Low Voltage and Electro Magnetic
Compatibility (EMC) Directives
– Work Equipment Directive – PUWER and LOLER
• Comprehensive risk assessments
• Guidance on technical file construction and
declaration of conformity/incorporation
• Pre-purchasing CE Audits
• Safety Related Control System validation

Machinery Safety Engineering Services
• Engineering design
– Site survey and function design specification
– Factory acceptance test
– Installation and commissioning
• Machine guarding
– Design, manufacture and installation of machine
guarding and Safety Related Control Systems
– Solutions include perimeter guarding, light
curtains, scanners, interlocking etc.

HSE Horse

• Machinery Directive
2006/42/EC
Legislation

• 1.3.7 Risks related to moving parts
• The moving parts of machinery must be designed
and constructed in such a way as to prevent risks of
contact which could lead to accidents or must, where
risks persist, be fitted with guards or protective
devices.
• 1.3.8 Choice of protection against risks arising
from moving parts
• Guards or protective devices designed to protect
against risks arising from moving parts must be
selected on the basis of the type of risk.
Machinery Directive EHSR’s

• 1.4.1 General requirements
• Guards and protective devices must:
− be of robust construction,
− be securely held in place,
− not give rise to any additional hazard,
− not be easy to by-pass or render non-operational,
− be located at an adequate distance from the danger
zone,
− cause minimum obstruction to the view of the
production process,

• 1.4.1 General requirements cont
• Guards and protective devices must:
− enable essential work to be carried out on the
installation and/or replacement of tools and for
maintenance purposes by restricting access
exclusively to the area where the work has to be
done, if possible without the guard having to be
removed or the protective device having to be
disabled.
• In addition, guards must, where possible, protect
against the ejection or falling of materials or objects
and against emissions generated by the machinery.

• 1.4.2.1 Fixed guards
• Fixed guards must be fixed by systems that can be
opened or removed only with tools.
• Their fixing systems must remain attached to the
guards or to the machinery when the guards are
removed.
• Where possible, guards must be incapable of
remaining in place without their fixings.

• 1.4.2.2 Interlocking movable guards must
− as far as possible remain attached to the machinery
when open,
− be designed and constructed in such a way that they
can be adjusted only by means of an intentional
action.
• Interlocking movable guards must be associated
with an interlocking device that:
− prevents the start of hazardous machinery functions
until they are closed and
− gives a stop command whenever they are no longer
closed.

• 1.4.2.2 Interlocking movable guards (cont) must
• Interlocking movable guards must be designed in
such a way that the absence or failure of one of their
components prevents starting or stops the
hazardous machinery functions.

• 1.6.4 Operator intervention
• Machinery must be so designed, constructed and
equipped that the need for operator intervention is
limited. If operator intervention cannot be avoided, it
must be possible to carry it out easily and safely.

Definition of a Safety Components
• Which serves to fulfil a safety function,
• which is independently placed on the market,
• the failure and/or malfunction of which endangers
the safety of persons.
Definition of a Safety Component

Safety devices that fall under the scope of the Directive
Annex V Indicative list:
• Extraction systems.
• Guards and protection devices.
• Control devices for calling lifting appliances and anti fall
devices for hoists.
• Protective devices designed to detect the presence of a
person.
• Safety belts and seat harnesses.
• Hydraulic non return valves where they are used to prevent
falls.
Definition of a Safety Component

• Provision and Use of
Work Equipment
Regulations 1998
Legislation

• Regulation 5 Maintenance
(1) Every employer shall ensure that work equipment is
maintained in an efficient state, in efficient working
order and in good repair.
(2) Every employer shall ensure that where any
machinery has a maintenance log, the log is kept up
to date.
PUWER 98 Regulations

• Regulation 11 Dangerous parts of machinery
(1) Every employer shall ensure that measures are
taken in accordance with paragraph (2) which are
effective –
(a) to prevent access to any dangerous part of
machinery or to any rotating stock-bar; or
(b) to stop the movement of any dangerous part of
machinery or rotating stock-bar before any part of a
person enters a danger zone.

(2) The measures required by paragraph (1) shall
consist of –
• (a) the provision of fixed guards enclosing every
dangerous part or rotating stock-bar where and to the
extent that it is practicable to do so, but where or to
the extent that it is not, then
(b) the provision of other guards or protection devices
where and to the extent that it is practicable to do so,
but where or to the extent that it is not, then

(b) be of good construction, sound material and
adequate strength;
(c) be maintained in an efficient state, in efficient
working order and in good repair;
(d) not give rise to any increased risk to health or
safety;
(e) not be easily bypassed or disabled;
(f) be situated at sufficient distance from the danger
zone;

• Explanation of safeguarding terms, regulation 11(2)
• GUARDS are physical barriers which prevent access
to the danger zone.
• FIXED GUARDS in regulation 11(2)(b) have no
moving parts and are fastened in a constant position
relative to the danger zone (see Figure 1).
• They are kept in place either
permanently, by welding for
example, or by means of
fasteners (screws, nuts etc)
making removal/opening
impossible without using tools.
PUWER 98 Regulations – Appendix II

• Explanation of safeguarding terms, regulation 11(2)
• If by themselves, or in conjunction with the structure
of the equipment, they ENCLOSE the dangerous
parts, fixed guards meet the requirements of the first
level of the hierarchy.
• Note that fixed enclosing guards, and other types of
guard, can have openings provided that they comply
with appropriate safe reach distances (see BS EN
13857).

• OTHER GUARDS in regulation 11(2)(b) include
movable guards which can be opened without the
use of tools, and fixed guards that are not fully
enclosing.
• These allow limited access through openings, gates
etc for feeding materials, making adjustments,
cleaning etc (see Figure 2).
• MOVABLE GUARDS may be power-operated, self-
closing, adjustable etc and are likely to require an
interlocking device so that:

(a) the hazardous machine functions covered by the
guard cannot operate until the guard is closed;
(b) if the guard is opened while hazardous machine
functions are operating, a stop instruction is given;
(c) when the guard is closed,
the hazardous machine
functions covered by the
guard can operate, but the
closure of the guard does
not by itself initiate their
operation.

• Adequate INFORMATION, INSTRUCTION, TRAINING
AND SUPERVISION are always important, even if the
hazard is protected by hardware measures, however,
they are especially important when the risk cannot be
adequately eliminated by the hardware measures in
regulation 11(2)(a) to (c).
• It may be necessary to lay down procedures to define
what information, instruction, training and supervision
must be given, and to restrict use of the equipment to
those who have received such instructions etc.

Control Measures
• Design the hazard out.
• Remove the need for man machine interface.
• Design in safeguards.
• Reduce the possibility of occurrence.
• Reduce the degree of harm.
• Warn and inform (but only if you can achieve
adequate safety).
.
Hierarchy Of Control

Use of Standards

• Can be used to demonstrate conformance with
regulations.
• Approved Codes of Practice refer to EN standards
• CE Marking Guidance refers to EN Standards
The Role of EN Standards

Machinery manufactured in conformity with
specified published European Harmonised
standards will be presumed to comply with the
Essential Health and Safety Requirements
covered by those standards
The Role of EN Standards

Now that’s what I call a hedge trimmer!

• Risk assessment must be carried out to
– Determine the limits of the Machinery
– Identify Hazards
– Estimate Risk and Evaluate
– Adequate Risk Reduction
• Design out hazard
• Reduce risk, lower power, speed etc
• Guard or protect
• Information and Warnings
• Re-assess and evaluate until acceptable
Risk Assessment (BS EN 12100:2010)

• Risk Reduction must consider
– Stability
– Maintainability
– Ergonomic Principles
– Electrical Hazards – BS EN 60204-1
– Hydraulic Hazards – BS EN 4413
– Pneumatic Hazards – BS EN 4414
– Safety related control systems – BS EN 13849/62061
– Electro Magnetic Compatibility (unexpected start)
Risk Assessment (BS EN 12100:2010)

• Mechanical risk
reduction
involves
removing or
reducing to a
minimum trap,
nip or pinch
points.
Risk Assessment

• To reduce risks from
debris and ejected parts
Risk Assessment

• A protection device or interlocking system should be
designed so that it will only operate as intended.
• Furthermore, if a component deteriorates or fails, the
device or system should as far as possible fail in a
safe manner by inhibiting the dangerous action of the
machine.
Safety Related Control System

EN 13849

• “A” type apply to all machines
• “B” type are designed to promote safety and split
into “B1” and “ B2”
• “C” type apply to a specific type of machine
Types of EN Standard

TYPE C
STANDARDS
for Machines
BS EN 12100- 2010
Safety of machinery,
general principles for
design and risk
assessment.
BS EN ISO 13857
Upper and Lower limb
access.
PR EN 418
Emergency Stop
SPECIFIC PROTECTIVE
DEVICE STANDARDS
2 Hand Controls
Light Curtains
Safety Switches etc
IEC 60204 - 1
Electrical
Equipment
BS EN 414
Safety of machinery
Rules for drafting and
Presentation of safety
standards
BS ISO 13850
Emergency Stop

Type A Standards
• Applies to all machinery and are essential reading
for machinery builders and modifiers
• BS EN 12100:2010 Safety of Machinery – General
principles for design – Risk assessment and risk
reduction (ISO 12100:2010)

'B1' Standards
• Apply to all machinery and are designed to promote
the essential factors mentioned in the foreword.
'B2' Standards
• These are "apply when used" Standards, i.e. if a
particular safety device is chosen for a machine,
then it must, be manufactured to the relevant
standard. E. g. Interlock switch, E stop switch.

Type B Standards
• BS EN ISO 13850 Emergency stops
• BS EN ISO 13855 Relates to the positioning of
Electro-sensitive protection devices. (light curtains,
pressure mats etc).
• BS EN 953 Safety of Machinery - Guards
• BS EN 1088 Interlocking devices associated with
guards
• BS EN 4413 Hydraulic systems.
• BS EN 4414 Pneumatic systems.
• BS EN ISO 13732-1 Hot surfaces

Type C Standards
• BS EN 415 Series Safety of Packaging Machines
• BS EN 10218 Industrial Robots Recommendations
for Safety. Parts 1 & 2.
• BS EN 12417 Safety of Machine tools Machining
Centres.
• BS EN 692 Mechanical Presses

• Scope
• This International Standard establishes values for
safety distances in both industrial and non-industrial
environments to prevent machinery hazard zones
being reached. The safety distances are appropriate
for protective structures. It also gives information
about distances to impede free access by the lower
limbs.
BS EN ISO 13857

• Use of Tables
• Reaching over protective structures:
• Table 1 shall be used where there is a Low Risk
• Table 2 shall be used where there is a High Risk.
BS EN ISO 13857

BS EN ISO 13857

• This standard enables users to avoid hazards
from crushing zones. It specifies minimum gaps
relative to parts the human body.
BS EN 349

BS EN 349

SCOPE
• This standard specifies general requirements for the
design and construction of guards provided to
protect persons from mechanical hazards.
BS EN 953

Risk assessment
• In order to select and design types of guards
appropriate to particular machinery, it is important to
assess the risk arising from the various hazards
present at that machinery and the foreseeable
categories of persons at risk !
• see EN ISO 12100
BS EN 953

• To minimise access to danger zones where
practicable, guards and machinery shall be so
designed as to enable routine adjustments,
lubrication and maintenance to be carried out
without opening or removing the guards.
• Where access is required within the guarded area
this shall be as free and unobstructed as practicable.
• Loading, unloading, setting, maintenance, jam
clearance, lubrication etc.
BS EN 953

Enclosing Fixed Guard

• Guards are used for numerous reasons including.
• Containment of ejected parts
• Containment of hazardous substances
• Noise reduction
• Radiation containment
• Explosion (blast panels designed to dissipate force)
• Viewing of process
BS EN 953

Distance Guarding - Fixed

• Guards must be suitable for purpose.
• Must be able to handle guards safely, not too heavy,
unstable, have handles if hard to lift.
• Movable guards or removable sections of guards
shall be designed to permit ease of operation.
• Guards shall be designed so far as is practicable to
take into account foreseeable use and reasonably
foreseeable misuse.
• Guards shall be designed so as not to cause
hazardous crushing or trapping points, with parts of
the machine or of other guards.
BS EN 953

Combination of Guards & Protective Devices

• Guards must be suitable for purpose.
• Guards shall be constructed so as not to have
exposed sharp edges and corners or other
hazardous projections.
• Guards shall be designed to withstand reasonably
foreseeable impacts from parts of machinery,
workpiece, broken tooling, ejected solid or fluid
matter, impact by the operator, etc.
• Materials and finishes used shall be non-toxic in all
foreseeable conditions of use.
BS EN 953

Distance Tunnel Guard

• Guards should be selected from the following in the
order of priority given:
a) Local guards enclosing individual danger zones if
the number of danger zones to protect is low. This
can provide an acceptable residual risk and permits
access to non-hazardous machine parts for
maintenance, setting, etc.
b) A guard enclosing all the danger zones if the
number or size of the danger zones is high. In this
case setting and maintenance points should, as far
as possible be located outside the guarded area.
BS EN 953 Selection of guards

• Guards should be selected from the following in the
order of priority given:
c) Partial distance guard if the use of an enclosing
guard is impracticable and the number of danger
zones to protect is low.
d) Fully surrounding distance guard if the use of an
enclosing guard is impracticable and the number or
size of the danger zones are high.
BS EN 953 Selection of guards

Suitability of guards

• Climbing on guards shall as far as practicable be
inhibited by design. Consideration shall be given to
this possibility in their construction and the selection
of materials and shapes.
• By eliminating horizontal structural members and
the horizontal component of mesh fabric from the
outside surface of the guard, climbing is made more
difficult.
BS EN 953

• Colour
• Hazards can be highlighted by the use of suitable
colours. For example if a guard is painted the same
colour as the machine and the hazardous parts
painted a contrasting bright colour, attention is
drawn to the hazard when the guard is opened or left
off.
BS EN 953

Tel. +44 (0) 1642 345637
Fax +44 (0) 1642 345643
E-Mail: paul.laidler@tuv-sud.co.uk
www.tuv-sud.co.uk
END

Machinery Safety. TÜV SÜD.pdf

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