SF04 - Safety System Development Process and Configuration Tools Overview

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

PUBLIC INFORMATION

Safety System Development Process & Configuration Tools

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED 2

Agenda

Closing & Wrap-up

Sample Project Utilizing the tools

Selection, Design, Verification, Development & Justification Tools

Safety Life-cycle Utilization

Safety System Development Process



3

Common Safety System

Development Process

Machine review & hazard

identification

Product Selection

Safety System Design

Safety System Installation

Start Production

Proper Safety System Development Process

Risk Assessment

Functional Specification Development

Product Selection

Structure Selection

Design

Design Verification

Installation

Verification & Validation

Training

Operation & Maintenance


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 safety devices/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 significant reductions in equipment utilization!

4

Most people have never been to a training session or have never read a machinery safety standard! This results in safety systems that are inadequate, ineffective & improperly designed.


The Proper Approach: A standards based methodology

5

Both US and International standards require a systematic approach for

safety system development which starts with a risk assessment!

So which method is right for you?

S1

S2

F2

F1

a

b

P1

P2

e

c

d

P1

P2P1

P2P1

P2

F2

F1

b

c

d

OR

ANSI/RIA TR15.306 MethodISO 13849 Method

Either is OK as long as you are following a risk assessment and risk reduction methodology!


Development Considerations!

• What machine/machines are to be guarded?

• What are the characteristics and limits of the machine/machines?

• What are the different modes of operation of the machine/machines?

• Who interacts with these machines during normal and abnormal operation?

• What are those people doing?• How does the machine need to function in

each 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 the

machine/machines?• What is the company specification?• What can be done to improve safety and

productivity?

What do I need to consider?


Agenda

Closing & Wrap-up






Rockwell Automation follows a “Safety Life-cycle” approach.

8

1. Assessment

The Machinery Safety Life-cycle is a defined process that is followed to ensure that proper safety practices have been

implemented!

5. Operate, Maintain & Improve

4. Installation & Validation

2. Functional Requirements

3. Selection, Design & Verification


Rockwell Automation follows the safety lifecycle to

evaluate machinery safety solutions because:

• It remove uncertainty and eliminates omissions and errors!• It provide a repeatable process that leads to complete safety

solutions.

An idea without a plan leads to indecision, omissions and mistakes!

The Safety Life-cycle’s Purpose

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 10

Step 1 in the Machinery Safety Lifecycle

is the Assessment!


1. Assessment




Proper safety system development starts here!


What is an

assessment and

how do I do it?

Step 1: The assessment.

The foundation of safety system development!

Machine Characteristics/Limits

Risk Evaluation

Hazard Identification

Risk Estimation

Risk Reduction

Risk

Tolerable

O

K

Too High

Risk Assessment Process

according to ISO12100



1. Assessment

4. Installation & Validation 2. Functional

RequirementSpecification

(SRS)3. Selection, Design & Verification

Step 2 is the Safety Requirements Specification!

The Safety Requirements Specification (SRS) defines the functional requirements of the safety system!


The main reason for developing a SRS

The SRS defines my solution!

• It identifies how the machine is to operate in each mode of operation for each person that interacts with the machine.

• It identifies special needs like: (Safe-speed/Safe-direction/Zone control/Etc.)

• It also identifies any special operational characteristics that are needed.



1. Assessment




Step 3 is the Selection, Design & design

Verification phase.

This step focuses on safety system design, product selection, circuit selection and design verification!


My assessment &

requirements spec

sure made this easy!

The design phase includes selection of mitigation techniques,

products, circuit & system structures.

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?

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

16

Mitigation Technique Selection

Design it out

Fixed enclosing guard

Monitoring Access /

Interlocked Gates

Awareness Means, Training and Procedures

(Administrative)

Personal protective equipment

Most Effective

Least Effective

Hierarchy of Protective Measures

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechEDCopyright © Rockwell Automation, Inc. All rights reserved. 17

Categories/Structure Selection

CAT

B/1

CAT 2

CAT 3 CAT 4 (higher diagnostic coverage that CAT 3)


Product Selection The risk assessment tool identified the required performance level

that is required for each part/portion of the machine. These products are grouped into Safety Functions.

Note: Safety Functions are made up of the following components:

Safety input devices/actuators

Safety control/logic devices

Safety output devices


How do I verify my design!

The design phase also includes design verification!

Design verification considerations:

• What do I need to do to verify my design?

• System structure

• Component reliability data/MTTFd or

B10d

• Diagnostic capability/DC.

• Design verification method/tool.

+ +

Structure Reliability Diagnostics


Design Verification Methods –Option 1 - Calculation Method

20

MTTFd Mean Time to Dangerous Failure

Low 0 -10 Years

Medium 10-30 Years

High 30-100 Years

DC Diagnostic Coverage = Detected Dangerous Failures / All Dangerous Failures

None DC < 60%

Low 60 < DC < 90%

Medium 90 < DC < 99%

High DC >99%


a

b

c

d

ePer

form

ance

Lev

el

Designated

Architecture

Designated

Architecture

Designated

Architecture

Designated

Architecture

Designated

Architecture

Designated

Architecture

Designated

Architecture

Cat B Cat 1 Cat 2 Cat 2 Cat 3 Cat3 Cat 4

DC 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 that the required PL is achieved by…Balancing Structure, Reliability and Diagnostic Coverage


Design Verification Methods –Option 2 - SISTEMA Method

22

SISTEMA is a free design verification tool that is

internationally recognized!



1. Assessment




Step 4 ensures that the system was installed properly and

that the system functions as intended!

This requires a documented installation plan and a documented process for verifying and validation that the system operates as intended.


How do I install my

safety system?

Step 4 - Installation

• Installation considerations:

• There should be specific:

• instructions regarding physical

barrier installation!

• instructions regarding safety

product installation and wiring!

• instructions regarding wiring

methods and grounding!

• instructions regarding panel

fabrication and wiring!

• instructions regarding signage

installation and location!

• layout drawings showing a routing,

mounting and installation

instructions!

• electrical schematics regarding

terminations & connections.


How do I validate my

safety system?

• Validation considerations:

• There should be specific instructions

regarding the validation of for each safety

function!

• This means that each safety input,

logic & output device must be tested

to confirm it functions as intended!

• This means that each combined

function of input/logic/output must be

tested to confirm it functions as

intended!

• This means that each programmed

function is validated to confirm it

functions as intended!

• There should also be specific instructions

regarding fault injection to test the safety !

• Common testing methods include:

• Shorting wires, breaking

connections, removing wires,

etc.

Step 4 Continued –Verification & Validation



1. Assessment




Step 5: Operate, Maintain and Improve confirms that the system

is operated properly and that the system is maintained

Step 5 focuses on confirming that the safety system remains effective.


How do I operate my

machine?

Step 5 – Operate, Maintain & Improve

• The should be training for all personnel

that will be interacting with the machine.

• The training should include:

• Intended use

• Safety system components training

• Normal operations

• Safety system operations


How do I maintain

my safety system?

Step 5 – Operate, Maintain & Improve

• The standards say that periodic testing

should be done to verify proper system

functionality. (There is no defined period or

timeline that is suggested)

• The standards also require additional

assessments after machine modifications.

This might include:

• Program changes

• Safety system use

• Hardware changes

• Machinery changes

• System modifications



1. Assessment




The Machinery Safety Lifecycle Never Ends!

The circle never ends. The system must be re-evaluated anytime modifications occur and each step must be followed!


Agenda

Closing & Wrap-up






There are a number of technologies and a lot of options.

That is why Rockwell developed selection tools.

• Simple Relay Solutions

• Modular, Programmable & Networkable Solutions

• Integrated PLC Solutions

• Safety Contactor & Relay Solutions

• Variable Frequency Solutions

• Integrated Motion Solutions

• CIP Safety™ for DeviceNet™ & EtherNet/IP™

• Low Cost Safety Networks

• Dual Port EtherNet/IP

• Emergency Stop Solutions

• Door interlock Solutions

• Presence Sensing Solutions

• Alternative Solutions


Starting with simple a Safety Logic Selection Matrix and …

Safety Relays

• 1 Zone

• Local/Hardwired I/O

• Simple Safety Logic

• 1 to 2 dual channel Inputs

• 2 to 3 outputs

Safety Controllers & Expandable

Relays

• 1 to 3 Zones

• Local & Distributed I/O

• Simple & Complex Safety

Logic


• 1 to 20 outputs

• Basic Diagnostics thru PLCSafety PLCs

• More Than 3 Zones

• Distributed I/O

• Simple & Complex Safety &

Standard Logic


• 1 to 100 outputs

• Advanced HMI Diagnostics


Simple Safety Output Selection Matrix and …

Safety Contactors & Relays

• Simple on/off control

• Power control

• Signal control

Safety Variable Frequency Drives

• On/off control with the ability

to control & monitor speed

Safety Servo Systems

• On/off control

• Speed control

• Direction control

• Position control

• Location control

• Acceleration control

• Deceleration control


a complete section and development tool like Safety Automation Builder.

34

Safety Automation Builder helps customer select complete bills of

material with automated selection guides.


Safety System Design Tools

35

Safety

Function

s

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.

Safety

Accelerato

r 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

Component

s

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


Safety Function Example

Safety Function: Emergency Stop

Products: Light Curtain /

GuardLogix®

Safety Rating: PLe, Cat. 4 to EN ISO 13849.1 2008

Complete Bills of Material, Schematics, Configuration Steps and

Programs.


Integrated Architecture® Safety Accelerator Toolkit

Development Tool and Quick Start Guide

Simplified Wiring

Preconfigured Logic

Quick Start Manual

Preconfigured HMI


Connected Component Building Blocks for Safety

38

Pre-designed Building Blocks with source code, drawings and quick-start

guide to help you develop safety solutions!


What is the Safety ROI Calculator Tool?

39

The industries only return on investment tool for safety projects!


ROI Example Output!

40

The Safety ROI tools helps customers justify safety projects based on

project cost and injury avoidance calculations!


Agenda

Closing & Wrap-up






Now let’s look at a sample machine!

We are going to use the safety tools to develop a safety solution utilizing Safety Automation Builder. This will leave us with a concept drawing, 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

safety functions, safety accelerator toolkit and connected components building blocks.

42


Machine Description

43

In-feed Conveyor

Out-feed Conveyor

Rotary Table

Label P&P

Label Feeder

Hot Glue GunProduct


Step 1 – Risk Assessment

We are going to develop a risk assessment utilizing

the ISO12100 evaluation method.

44

S1

S2

F2

F1

a

b

P1

P2

e

c

d

P1

P2P1

P2P1

P2

F2

F1

b

c

d


Step 2 Develop the Functional Specification

Normal operation Maintenance Set-up Adjustment Change-over Start-up Decommissioning Etc.

45

Identify the hazards and associated risks! Develop a functional specification that outlines how each hazard needs to be protected for each mode of operation.

Thermal Hazard

Crushing Hazard

Pinching Hazard

Pinching Hazard

It is estimated that 60 to 70% of all injuries happen outside of normal production activities

yet most people spend 90% of their efforts around designing for production activities!


Next Step Define Our Safety Functions

When Door Opens in zone #1, tray packing stops, zone #2, tray forming continues.

Safety Function: Safety related stop initiated by a

safe guard

Stopping hazardous movement

Identify the product characteristics that are needed to fulfill the requirements.

Zone #1 Zone #2

Follow This Process for Every Safety Function in Every Machine Mode!


Step 3: Develop a safety project utilizing Safety Automation Builder.

47

This screen shot shows the layout drawing with identified hazard locations

and access points that need to be protected!


Users can now start the safety selection process by selecting

input, logic and output devices for each identified safety need!

48

This screen shot shows the layout drawings with the selected safety devices!


Users can verify their design by exporting the SAB file to

SISTEMA for design verification! This is a sample report.

49

This screen shot shows the safety design verification report from SISTEMA!


Users can create completed Bills of Material from ProposalWorks &SAB!

50

This screen shot shows the completed bill of material for the labeler

machine safety system!


Now that we have a price! We can justify the investment!

51

We will use the Safety Return on Investment Tool to justify the project based on projected reductions of injuries and productivity enhancements!

Let’s calculate our savings and ROI for this machine example!


The next step after selection, design verification & justification is design!

52

Now we need to start making schematics, developing programs and configuration documents. The Safety Function documents can help!

The Safety Functions documents are found on the safety resource center!


An additional tool that can help is the Safety Accelerator Toolkit

53

Safety Accelerator Toolkit

The Safety Accelerator Toolkit can be found on the safety resource center or

by asking your local Rockwell Automation distributor!


An additional tool that can help is Connected Component

Building Blocks for Safety

54

The Safety Building Blocks can be found by asking your local Rockwell

Automation distributor for a CD!


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 system performance.

Performed an ROI analysis demonstrating the value of the safety system

Leveraged example code, faceplates, wiring diagrams etc.

55

Complete documentation for your safety solution!


PUBLIC INFORMATION

Summary


Rockwell Automation the global leader in safety (Services/Products/Solutions)!

Best in class assessment services to help you to determine

safety system needs!

Safety Design Tools and resources to help engineers and

designers with safety system development.

Products selection and design verification tools to helps

engineers select product quickly and accurately.

Installation and start-up services to help meet productivity and

start-up needs.

Validation services to confirm the safety system operates as

designed and constructed.

Preventive maintenance development services to confirm the

safety system continues to operate properly.


PUBLIC INFORMATION

Questions?

SF04 - Safety System Development Process and Configuration Tools Overview

Technology

Transcript of SF04 - Safety System Development Process and Configuration Tools Overview