Machinery and CE Marking Day 2 - saferoption.com - Machinery Safety - Day 2 September 2015... ·...

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Machinery and CE Marking – Day 2

Programme – Day 2 • Low Voltage Directive

• Pressure Equipment Directives

• A Type Standard - BS EN ISO 12100 – Dangerous Parts and Hazards of Machinery

– Life Cycle Task Identification

• Example B Type Standards, eg – Anthropometrics (BS EN ISO 14738)

– Human Body Measurement (EN 547)

– Means of Access to machinery (ISO 14122)

– Size of Openings BS EN 13857

– Control Systems (BS EN 13849)

• Example C Type Standards, eg – BS EN 13128 – Milling machines

• Modified and Composite Assemblies

• Information to End Users

EU Guidance – Points to Note

• In general, the Machinery Directive does not apply to the placing on the market of used or second-hand machinery.

– Except machinery that was first made available with a view to distribution or use outside the EU, when it is subsequently placed on the market or put into service for the first time in the EU.

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• Once the reference of a harmonised standard has been published in the OJEU, its application confers a presumption of conformity with EHSRs covered.

• “date of cessation” given for superseded standards

• During transition either standards confer presumption


• Where a standard is referred by a normative reference in a EU harmonised standard, the specifications of the standard referred to become part of the harmonised standard and their application confers a presumption of conformity with the EHSRs covered.

• This remains true, even if the standard referred to is no longer in force.

• The application of the latest version of the standard also confers a presumption of conformity


• When a manufacturer chooses not to apply harmonised standards or to apply only parts of a harmonised standard, he must include in the technical file the risk assessment undertaken and the steps taken to comply with the EHSRs.

• In such a case, the reference of the harmonised standard should not be listed in the Declaration of Conformity

• But the Declaration may indicate which parts or clauses of a harmonised standard have been applied.

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HSE Guidance – Point to Note

–Prior to the introduction to European product safety Directives, with supporting transposed harmonised standards, many products met National standards. In the UK for machinery we had a long standing comprehensive British Standard BS 5304 Code of practice for the safety of machinery.


–But any standards in conflict with or superseded by European standards have had to be withdrawn, including BS 5304: 1988 as it was superseded by various European standards which apply to new machinery.


– However, much old existing machinery is still in use for which the new European standards can't be retrospectively applied, and so for this situation the text of BS 5304 (with some updating) was republished as Published Document PD 5304:2014 Guidance on safe use of machinery.

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– So, for pre Machinery Directive equipment (that is put into use before 1995) this remains the guide to what is considered reasonably practicable for the safety of machinery.

OTHER PRODUCT DIRECTIVES

LOW VOLTAGE DIRECTIVE

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Low Voltage Directive

• Implemented in UK as Electrical Equipment (Safety) Regulations 1994

• Place duties on manufacturer or authorised representative

• All relevant electrical equipment to comply from Jan 1997

• Equipment between

– 50 and 1000v AC

– 75 and 1500v DC


• Electrical equipment to be

– Safe

– Constructed in accordance with good engineering practice

– Electrical equipment which satisfies harmonised standards shall be taken to comply

– Where no harmonised standards exist, international standards applied will comply

– Where no international standard, national standards will be taken to comply


• CE Mark to be affixed to appliance (or to packaging, instruction sheet or guarantee certificate)

• A declaration of conformity must be drawn up

– Does not need to be issued.

– Available to inspect by enforcing authority on request.

• Technical documentation to be compiled

– Available for 10 years after manufacture of equipment has ceased

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• Applies to equipment provided by the manufacturer for use in own premises

– In such cases there is no need to CE mark


• Declaration of conformity

– Name and address of the manufacturer or his authorised representative;

– Description of the electrical equipment;

– Reference to the harmonised standards;

– References to the specifications with which conformity is declared;

– Identification of the empowered signatory

– Last two digits of the year in which the CE marking was affixed.


• Technical Documentation

– General description of the electrical equipment;

– Designs, drawings and circuit diagrams

– Operation information

– List of the standards applied in full or in part

– Solutions adopted where standards not applied

– Design calculations , examinations carried out

– Test reports.

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• Safety Principles

– Information on safe use marked on equipment or separate notice

– Manufacturer’s brand / trade mark clearly printed on equipment or, if not possible, packaging

– Constructed so assembly and connection is safe


• Protection against hazards from the equipment

– Persons and domestic animals protected against direct and indirect contact

– Dangerous temperatures, arcs or radiation not to be produced

– Insulation to be suitable for conditions

– Overload protection

– Mechanically sound


• Changes from 2016 – New exception

• Custom built evaluation kits destined for professionals to be used solely at research and development facilities for such purposes

– Electrical equipment which satisfies harmonised standards shall be presumed to comply

– Ongoing testing and register of complaints

– Equipment should bear an identification number,

– Instructions to be supplied

– Technical documentation to include risk assessment

– Clarification of duties on importers

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PRESSURE EQUIPMENT

Pressure Equipment Directive

• Implemented in UK by Pressure Equipment Regulations 1999 (New directive from 19th July 2016)

• Duties on manufacturer or authorised representative

• Covers pressure equipment which includes: – Vessels

– Piping

– Safety accessories

– Pressure accessories

– Assemblies


• Pressure equipment

– Equipment and assemblies of pressure equipment with a maximum allowable pressure over 0.5 bar

– Will need to be classified and be allocated a category taken from relevant charts

– The allocated category will dictate the conformity procedure to be followed

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• Chart Allocation


• Chart Allocation

– Fluid Group 1 (To be amended on June 1st 2015 in line with CLP)

• Explosive

• Extremely flammable

• Highly flammable

• Flammable

• Very toxic

• Toxic

• Oxidising

– Fluid Group 2 • All other fluids including steam


• Chart 1

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• Chart 5


• Chart 6 – Piping Group 1 gases

• Chart 7 – Piping Group 2 gases

• Chart 8 – Piping Group 1 liquids

• Chart 9 – Piping Group 2 liquids


• Pressure equipment and assemblies below specified pressure/volume thresholds must: – Be safe

– Be designed and manufactured according to ‘sound engineering practice’ (SEP) • Means the use of industry standards and practices

• Bbeen in use for many years and have demonstrated their safety over time.

– Be accompanied by adequate instructions for use; and

– Bear specified markings (but not the CE marking).

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• Pressure equipment and assemblies above specified pressure/volume thresholds must: – Be safe

– Meet essential safety requirements covering design, manufacture and testing (Including information) • ‘Type C’ Standards available

– Satisfy appropriate conformity assessment procedures and are accompanied by a declaration of conformity

– Carry the CE marking and other information


• Appropriate Conformity assessment procedures

• Categories are taken from charts 1-9

• Changes to modules July 2016


• Appropriate Conformity assessment procedures

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• Technical documentation – a general description of the pressure equipment

– conceptual design and manufacturing drawings

– descriptions and explanations necessary for an understanding of the drawings and the operation of the pressure equipment

– a list of the harmonised standards applied and solutions adopted where standards not applied

– results design calculations made, examinations carried out etc

– Test results

SIMPLE PRESSURE VESSELS

Simple Pressure Vessels

• Pressure vessels containing air or nitrogen over 0.5 bar but less than or equal to 30 bar

– Excluded from the Pressure Equipment Directive

– Classed as simple pressure vessels

– Supply covered by the Simple Pressure Vessels Directive

– Duties on manufacturer or authorised representative

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• Pressure vessels with stored energy below 50 bar. Litres: (Category B vessels)

– Manufactured in accordance with engineering practice recognised as sound in the European Union

– Bears the specified inscriptions (but not the CE marking)

– it is in fact safe.


• Pressure vessels with stored energy below 50 bar. Litres: (Category B vessels)

– Specified inscriptions

• maximum working pressure in bar

• maximum working temperature in °C

• minimum working temperature in °C

• capacity of the vessel in litres

• name or mark of the manufacturer

• type and serial or batch identification of the vessel


• Pressure vessels with stored energy above 50 bar. Litres: (Category A vessels)

– Meet the essential safety requirements

– Have safety clearance from an approved body

– Bear CE marking and other specified inscriptions;

– Be accompanied by manufacturer's instructions;

– Be safe

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HAZARDS OF MACHINERY

Machinery Precautions

• Dangerous Parts – PUWER Reg. 11 requires

• Measures to prevent access to dangerous parts of machinery; or

• Stop movement before person enters a danger zone

Machinery Precautions

• Dangerous Parts – Supply of Machinery (Safety) Regulations 2008,

specifies • 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.

– All necessary steps must be taken to prevent accidental blockage of moving parts involved in the work.

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Standards

– A - Type

• All machines

• Not sufficient on their own

–B - Type

• Specific aspect or safeguard

• Gives presumption to EHSR

– C - Type

• Specific to a given category of machine

• Takes precedent when different to A or B

• Gives presumption to EHSR

Dangerous Parts

Classified in Harmonised European Standard – BS EN 12100 (Type A)

– Mechanical Hazards (Consequences) • crushing

• shearing

• cutting or severing

• entanglement

• drawing-in or trapping

• impact

• stabbing or puncture

• friction or abrasion

• high pressure fluid injection

Dangerous Parts

• Crushing

Typically between moving

object and fixed object

References taken from PD5304 - Guidance on safe use of machinery

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Dangerous Parts

• Shearing

Scissor action between 2 components

Dangerous Parts

• Cutting and Severing

Contact with moving blades and cutters

Dangerous Parts

• Entanglement

Exposed rotating parts

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Dangerous Parts

• Drawing in or trapping

Fingers, limbs or whole

body can be drawn in

between counter-

rotating parts or where

power is being

transmitted through

belts or pulleys

Dangerous Parts

• Impact

By moving machines or components

Dangerous Parts

• Stabbing and puncture

Ejection of a sharp

component, or where there

is a point interface

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Dangerous Parts

• Friction or abrasion

contact with fast rotating objects

Machinery Hazards and Consequences

• EN ISO 12100 – Safety of Machinery – Risk Assessment

– Gives examples of the origin of hazards, and

– Relates the hazard to potential consequences.


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Machinery Hazards

Non mechanical hazard groups (EN ISO 12100)

• Electrical

• Thermal

• Noise

• Vibration

• Radiation

• Hazardous materials & substances

• Ergonomic

• Working environment

• Combination of hazards

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Life Cycle Task Identification

• BS EN ISO 12100 (Table B.3)





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PRACTICAL ELEMENT NO. 3

Lawn Mower

– Name – Rotary Lawnmower

– Input – 230v

– Power – 1600w

– Size – 380mm blade

– Weight – 20Kg

– Lifetime – 10 years

• In groups:

– Identify the lifecycles for the lawnmower

– For two of the identified lifecycles, identify 3 tasks

– For each task identify 3 hazards or hazardous situations

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Hazardous Events (Examples)






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SPECIFIC CONSIDERATIONS OF MACHINERY SAFETY AND DESIGN

Specific Considerations

• BS EN ISO 14738 – Safety of machinery – Anthropometrics

requirements for the design of workstations at machinery: • Task requirements

• Determination of main work posture

• Dimensional data for workstation design

• Sitting – Working height, working

surface height and slope

– Seat

• Raised sitting

• Standing with support

• Standing

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Degrees of Protection Afforded by Enclosures

• BS EN 60529 – IP Coding

Degrees of Protection Afforded by Enclosures IP Coding

• 1st Character – Protection against solids

– Protection of the person


• 1st Character – Protection against solids

– Protection of the equipment

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• 2nd Character Protection against liquids

IP44

IP55

IP54

Specific Machinery Standards

• Safety of Machinery – Human Body Measurement – EN 547

• Part 1 – Principles for determining

the dimensions required for openings for whole body access into machinery

• Part 2 – Principles for determining the

dimensions required for access openings

• Part 3 – Anthropometric data


• Safety of Machinery – Human Body Measurement

342mm + 20mm clothing

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• Working Platforms – 14122-2

Access and Egress

• ISO 14122/1 – Choice of fixed access

– Types

Access and Egress

• ISO 14122/1 – Basic solutions

– Preferred access

• If level access according is not possible or practicable,

• a lift, or

• suitable ramp with an angle of pitch less than 10 °, or

• stairs with an angle of pitch from a minimum of 30 ° to maximum of 38 °

– shall normally be selected as a safe and suitable basic solution for the necessary access.

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Access and Egress

• ISO 14122/1 – Conditions for the selection of stepladder or ladder

– stepladders and ladders shall be avoided as far as practicable

– If preferred access means are not possible, selection of a stepladder or ladder may be considered

– Final decision based on risk assessment (EN12100)

– If the level of risk is too high, the means of access to the machine shall be changed

Access and Egress

• ISO 14122/1 – cases when a stepladder or ladder may be selected (More than one required)

– Short vertical distance

– Infrequent use

– No large tools carried

– One person at a time

– Not used for evacuation of injured persons

– Structure does not make stairs possible.

Access and Egress • ISO 14122/3

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Access and Egress

• ISO 14122/2 – Working Platforms and walkways

– Construction and materials

– Safety of operators

– Specific requirements • Location

• Dimensions

• Facilities or equipment

• Floorings

• Design loads

– Assembly instructions

– Annex A Different methods of determining levels of slip-resistance

Access and Egress

• ISO 14122/2 – Working Platforms and walkways

– Width • 600mm to 800mm (Unless exceptional circumstances)

• 1000mm where persons cross simultaneously

• Can be reduced to 500mm when justified by risk assessment

– Headroom (Ref to EN547) • 2100mm min unless exceptional circumstances

exist

• Can be reduced to 1900mm when justified by risk assessment

– Risk assessment justification • the working platform or walkway is used only occasionally, or

• the reduction is made only for a short distance

Access and Egress • ISO 14122 -3 – Stairways, stepladders and guard-rails

– Required when fall is over 500mm

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Declaration Jig 19

Access and Egress

• ISO 14122/2 – Working Platforms – Falling objects

– Flooring to have maximum opening of 35mm dia where occasional passage beneath

– Max opening of 20mm dia otherwise.

– No opening where falling object risk is more significant than other risk

Dimensions included in BS4592-0

MACHINE GUARDING

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Machine Guarding Hierarchy

PUWER Reg 11

• The provision of fixed guards enclosing every dangerous part where it is practicable to do so, if not then;

• The provision of other guards or protection devices where it is practicable to do so, if not, then

• The provision of jigs, holders, push-sticks or similar protection appliances where it is practicable to do so,

AND

Training, Information, Instruction and supervision as is necessary

Machine Guarding Hierarchy

Supply of Machinery (Safety) Regulations 2008

• Guards or protective devices designed to protect against risks arising from moving parts must be selected on the basis of the type of risk. The following guidelines must be used to help to make the choice.

Choice of Protection against Moving Parts

• Supply of Machinery Regulations 2008

– Annex I – EHSRs – 1.3.8

• Transmission parts – Fixed, or

– Interlocked

• Interlocks used where frequent access is envisaged

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• Supply of Machinery Regulations 2008 – Annex I – EHSRs – 1.3.8

• Moving parts involved in the process – Fixed, or

– Interlocked, or

– Protective devices, or

– A combination of the above

• Where process moving parts cannot be made inaccessible due to required operator intervention, then – Fixed, interlocked or adjustable guards shall be used to

prevent access to those parts that are not needed in the work.

Choice of Protection against Moving Parts • BS EN ISO 12100

(section 6)


EN 953

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Guarding Types

• BS EN ISO 12100

– Fixed guard

• guard affixed in such a manner (e.g. by screws, nuts, welding) that it can only be opened or removed by the use of tools or destruction of the affixing means

Guarding Types

• Supply of Machinery Regulations 2008 – Annex I – EHSRs – 1.4.2

• Fixed guard – 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

• (See BS EN 953)

Guarding Types

• BS EN ISO 12100 – Moveable Guard

• guard which can be opened without the use of tools

– Adjustable Guard • fixed or movable guard which is adjustable as a whole or which

incorporates adjustable part(s). The adjustment remains fixed during a particular operation

– Supply of Machinery Regulations 2008 refer only to Adjustable Guards the definition of which combines the above 2 requirements.

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Guarding Types

• BS EN ISO 12100 – Interlocking Guard

• guard associated with an interlocking device so that, together with the control system of the machine, the – following functions are performed:

» the hazardous machine functions "covered" by the guard cannot operate until the guard is closed;

» if the guard is opened while hazardous machine functions are operating, a stop command is given;

» when the guard is closed, the hazardous machine functions "covered" by the guard can operate. The closure of the guard does not by itself start the hazardous machine function.

Type B Standard – EN14119

Guarding Types

• BS EN ISO 12100 – Interlocking guard with locking – Interlocking guard with start function

• Protective Devices – Hold to run device – 2 handed control – Sensitive protective equipment – Active opto-electronic protective device – Mechanical restraint – Limiting device

Guarding Types

• PD 5304

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Selection of Guards

• BS EN ISO 12100 – Where access to the hazard zone is not required during

normal operation

a) fixed guard

b) interlocking guard with or without guard locking

c) self-closing guard

d) sensitive protective equipment, e.g. electro-sensitive protective equipment or pressure sensitive mat.

Selection of Guards

• BS EN ISO 12100 – Where access to the hazard zone is required during

normal operation

a) interlocking guard with or without guard locking

b) sensitive protective equipment, e.g. electro-sensitive protective equipment

c) adjustable guard;

d) self-closing guard

e) two-hand control device

f) interlocking guard with a start function (control guard)

Selection and Design of Guards

• Guard Selection – Other Standards

– EN 953 - Safety of machinery –

• Guards – General requirements for the design and construction of fixed and movable guards

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• General requirements for the design and construction of fixed and movable guards – BS EN 953 (ISO 14120)

– Includes:

• Danger zones

• Ejected parts

• Substances

• Noise

• Radiation

• Explosion

• Human aspects

• Crushing points

• Durability

• Hygiene

• Cleaning

• Sharp edges

Specific Guarding Standards

• General requirements for the design and construction of fixed and movable guards – BS EN 953 (ISO 14120)

– Includes:

• Integrity

• Ejected parts

• Tool removal

• Self closing guards

• Adjustable guards

• Moveable guards

Self Closing Guard Hinged Interlocked Guard

Specific Guarding Standards

• BS EN 953

– Guard Types

Fixed Guard

Distance Guard

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• Guard Selection – Other Standards

– EN 13857 - Safety of machinery -

• Safety distances to prevent hazard zones being reached by upper and lower limbs – Reaching Upwards

– Reaching over

– Reaching around

– Reaching through


• EN 13857 - Safety of machinery -

– Size of openings


• EN 13857 - Safety of machinery -

– Size of openings

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• Interlocks on guards – Guard covered by EN953 – Interlock parts

covered by EN14119 – Processing of signal

from interlock to machine • EN13849

Interlocks – EN 14119

Interlocks – EN 14119

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CONTROL SYSTEMS

Control Systems

Control Systems

• EN13849 requires:

– To establish the performance level (Pl) of the entire system

– Select the required category of the system or component architecture.

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Control Systems – Calculation of PL

Control Systems – EN13849-1

‘C TYPE’ STANDARDS

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C Type Standards

• Provide specifications for a given category of machinery

• C-type standards may refer to A or B-type standards – indicating which of the specifications of the A or B-type

standard are applicable to the category of machinery

• When a C-type standard deviates from the specifications of an A or B-type standard – the specifications of the C-type standard take precedence

• Application of C-type standard gives presumption to EHSRs

C Type Standards

• Milling Machines – EN 13128

• Drilling Machines – EN 12717

• Machining Centres – EN 12417

• Robots – ISO EN 101218

• Circular Saws - EN 1870

• Mechanical Presses – EN 692

• Hydraulic Presses – EN 693

• Compressors – EN 1012

• Etc.

EN 13128 – Milling Machines

• Definition

– a machine designed to shape cold metal by the use of a rotating cutting tool

– Manual Milling machine

• powered single axis motion without the capability for programmed multiple axis movements

– Automatic milling machine

• a machine capable of performing programmed multiple axis movements

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• Definition

– a machine designed to shape cold metal by the use of a rotating cutting tool

– Manual Milling machine

• powered single axis motion without the capability for programmed multiple axis movements

– Automatic milling machine

• a machine capable of performing programmed multiple axis movements


• Hazards


• Requirements

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• Requirements


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• Requirements



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EN 23125 – Turning Machines

• Control Systems

PRACTICAL ELEMENT NO. 4

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Practical No 4 - Assignment

• Visit the pre-arranged workplace

• Select a machine to assess

• Identify two lifecycles

• Using the supplied risk assessment spreadsheet template

• Undertake a machinery risk assessment for each of the lifecycles identified

Machinery and CE Marking Day 2 - saferoption.com - Machinery Safety - Day 2 September 2015... ·...

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Transcript of Machinery and CE Marking Day 2 - saferoption.com - Machinery Safety - Day 2 September 2015... ·...