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Introduction to Functional Safety ISO 13849 and EN 62061
Module T3
A specialist technical Training module from the Machine Safety training series
27.9.13 Replaces None Created by S.Steele
Why are we doing this?
The EU Machinery Directive (98/42/EC),
As a European law, defines the targeted levels of Machine Safety.
Compliance with machinery directive is necessary
to get the CE mark, and to Allow the free circulation of machinery
within the European Union.
A new version will be effective at the end of 2009
The European harmonised standards
Established technical specifications which comply with the
requirements of the related directives.
Compliance with European Harmonised standard give compliance
with the related directive
Comply with the European harmonized Standards is the simplest
way to comply with the Machinery Directive
European legislation and the standards
Why are we doing this?
European legislation and the standards
If you are creating a complex assembly by interlinking a
series of existing machines you are in effect creating
something new.
• Therefore who ever is carrying out the work must ensure
that the whole assembly complies with the Directive.
• Regardless of the age of the machines.
• If you are altering the function or performance of a
machine or complex assembly you are again creating
something new and must ensure that the Directive is
complied with.
Before we begin The Terminology
Standard types: A-B1-B2-C
Design architecture categories: B-1-2-3-4
(PL) Performance level: A-B-C-D-E
(SIL ) safety integrity level : 1-2-3-4
(CCF) Common cause failure
failures of different items, resulting from a single event, where these failures are not
consequences of each
other
(SRP/CS) Safety-related part of a control system
part of a control system that responds to safety-related input signals and generates safety-
related output
Signals
(MTTFd ) Mean time to dangerous failure
expectation of the mean time to dangerous failure
(DC) Diagnostic coverage
measure of the effectiveness of diagnostics
Standards overview Safety circuit design
On the basis of the risk assessment, the designer has to define the safety
related control system. To achieve that, the designer will chose one of the
two standards appropriate to the application:
either standard EN/ISO 13849-1, which defines performance levels
(PL)
or standard EN/IEC 62061, which defines safety integrity levels (SIL)
The table below gives relations between these two definitions
To select the applicable standard, a common table in both standards gives
indications:
-
d
Standard EN/ISO 13849-1
• The Standard gives safety requirements for the design and integration of safety-
related parts of control systems, including software design.
• The Risk Graph helps to determine the required PL (Performance Level) of each
safety function
– S - Severity of injury
> S1 Slight injury
> S2 Serious or permanent injury or death
– F - Frequency and / or exposure to a hazard
> F1 Seldom to less often and / or short time
> F2 Frequent to continuous and / or long time
– P - Possibility of avoiding the hazard or limiting the harm
> P1 Possible under specific conditions
> P2 Scarcely possible
Standard EN/IEC 62061
• Specific to the machine sector within the framework of EN/IEC 61508:
– gives rules for the integration of safety-related electrical, electronic and electronic programmable control
systems (SRECS)
– does not specify the operating requirements of non-electrical control components in machine (ex.: hydraulic,
pneumatic)
• The probability of failure associated to the required SIL (Safety
Integrity Level) depends on the frequency of usage of the safety
function to be performed
Safety of Machinery
application
EN/IEC 62061
Introduction to Functional Safety
The standard EN ISO 13849
A basic std
EN ISO 12100
Fundamental notions,
Design main principles
EN 693
hydraulic Presses
EN 692
Mechanical presses
C specific class of machines
EN 1088
Locking devices
EN 953
Fixed and mobile protectors
EN/ISO 13850:2006
Emergency
Stop equipment
EN 574
Bi-manual
command devices
B2 safety devices
EN 1050 = EN/ISO 14121
Risk assessment
EN 954-1 = ISO 13849-1:1999
 EN ISO 13849
Safety of machinery
Safety-related part of ctrl sys
EN 60 204-1
Machines electrical
equipment
EN 294 and 999
Safety distances
B1 specific safety aspect
The 13849 standard
Parts of machinery control systems that are assigned to provide safety functions are called safety-related
parts of control systems (SRP/CS) and these can consist of hardware and software and can either be
separate from the machine control system or an integral part of it. In addition to providing safety functions,
SRP/CS can also provide operational functions (e.g. two-handed controls as a means of process initiation).
The ability of safety-related parts of control systems to perform a safety function under foreseeable
conditions
They are allocated one of five levels, called performance levels (PL). These performance levels are defined
in terms of probability of dangerous failure per hour .
The probability of dangerous failure of the safety function depends on several factors, including hardware
and software structure, the extent of fault detection mechanisms [diagnostic coverage (DC)], reliability of
components [mean time to dangerous failure (MTTFd), common cause failure (CCF)], design process,
operating stress, environmental conditions and operation procedures.
Safety Control function
Working example
Who is the designer who is the
manufacturer?
We are as we are upgrading the control
system
Is this a significant change to line 2 filler as defined in the directive?
No as we are not changing the functionality technically but we are
improving the existing controls .
So re-CE Marking is not required
Working example Electrical control system
upgrade
Note: Under PUWER assessment the electrical control system does not comply
with BS EN 60204 Ref: General electrical requirements
(Enacted in 17th
edition).
Integrity assessment First step
Integrity assessment First step
Alternative PL Tools
SISTEMA Software PL Calculation Tool
SISTEMA is a software tool for the implementation of EN ISO 13849-1. Its
use will greatly simplify the implementation of the standard.
SISTEMA stands for "Safety Integrity Software Tool for the Evaluation of
Machine Applications" It was developed by the BGIA in Germany and is free
for use.
Second step
SAFETY FUNCTION DESIGN
Performance Level Data:
When configured correctly, the safety system can achieve a safety rating of PLd, Cat. 3
according to EN ISO 13849.1 2008.
When modeled in SISTEMA, each safety E-stop string is treated as an individual safety
function and can be modeled as follows. This diagram shows a single E-stop safety
function.
Calculations are based on 1 operation of the E-stop per month, with 12 operations per
year; therefore 36 operations of contactors per year. The Diagnostic Coverage (Dcavg)
is reduced to 60% for the E-stops because they are connected in series.
SISTEMA File:
Second step
SAFETY FUNCTION DIAGRAM
Process stop
other equipment
Third step
PL FUNCTION VALIDATION OF DESIGN FOR THE
SAFETY CONTROL SYSTEM
Function design Validation
(Refer to training module T2 for EOL Tool kit to undertake assessments and validation of circuit designs)
First part Identifies the control systems required and their PL requirement
Each section is taken individual and circuit function generated to achieve PL
requirement
Working example
electrical drawings Emergency stop
PONZ S4
PONZ S7
Working example
electrical drawings main drive inverter
Safety
Relay
activation
Working example
Drive inverter Technical details
Working example
Drive inverter Technical details
S.steele functional safety ppt
Working example
Working example
Old machinery in this context are machines which were placed on the market before the
Machinery Directive came into force. The requirements of the directive were not applied to these
machines. However, its application may become necessary should machines be extended,
modified, modernized, etc. In such cases, assess- ment must be made for whether an essential
change has occurred. Should this be the case, the requirements of the EC Machinery Directive
apply to “old” machines in the same way as to new machinery. These requirements include the
application of EN ISO 13849.
Treatment of old machinery
Design categories
Architecture Overview
Design architecture and PL Overview
PL
Relationship Between Different
Criteria
• Relationship between Categories,
DCavg, MTTFd and PL
*In several application the realisation
of performance level c by category 1
may not be sufficient. In this case a
higher category e.g. 2 or 3 should
be chosen.
Working example
Example 1: Emergency stop Safe Stop - Category B, PL b
Design categories example Cat 2 Architecture
EMERGENCY STOP, Category 2
single-channel,with feedback circuit
Working example
Example 2: Emergency stop with Safe Stop using safety relay -
Category 3, PL d
Design category example CAT 3 architecture
EMERGENCY STOP, 2-channel,
Category 3
Working example
Example 3:Emergency Stop of frequency converter with Safe Stop, Safety
Relay and output contactor - Category 4, PL e
Safety Chain Principle for Design
Use devices that
comply with safety
standards
Monitor & analyze
the information
Safety-oriented signal
processing
Catch the
information
Safeguarding to protect
people from hazard
Initializing & control
of hazardous machine
Emergency stop
operations
Stop the dangerous
machine
Signalling
Disconnection
and locking
power supply
Safe drive
technology
Safe signal transmission
Safe connection & communication of functional units or segments
Functional Safety Life Cycle
Safety LifeSafety Life
CycleCycle
STEP 5STEP 5
MAINTAIN & IMPROVE
SAFETY SYSTEM
STEP 1STEP 1
RISK OR HAZARD
ASSESSMENT
STEP 4STEP 4
SAFETY SYSTEM
INSTALLATION &
VALIDATION
STEP 2STEP 2
SAFETY SYSTEM
FUNCTIONAL
REQUIREMENTS
(Conf
STEP 3STEP 3
SAFETY SYSTEM
DESIGN & VERIFICATION
Other Modules in the S.Steele specialist technical Training module series
T1 Introduction to EU Directive & Harmonization standards
T2 EHSR Compliance & EOL Tool kit
T3 Functional safety of control system design
T4 Guarding fixed and movable
T5 Electrical systems
T6 EMC
T7 Robots
T8 Hydraulic
T9 Pneumatic
T10 HP Air systems
T11 EC Marking Equipment
END

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S.steele functional safety ppt

  • 1. Introduction to Functional Safety ISO 13849 and EN 62061 Module T3 A specialist technical Training module from the Machine Safety training series 27.9.13 Replaces None Created by S.Steele
  • 2. Why are we doing this? The EU Machinery Directive (98/42/EC), As a European law, defines the targeted levels of Machine Safety. Compliance with machinery directive is necessary to get the CE mark, and to Allow the free circulation of machinery within the European Union. A new version will be effective at the end of 2009 The European harmonised standards Established technical specifications which comply with the requirements of the related directives. Compliance with European Harmonised standard give compliance with the related directive Comply with the European harmonized Standards is the simplest way to comply with the Machinery Directive European legislation and the standards
  • 3. Why are we doing this? European legislation and the standards If you are creating a complex assembly by interlinking a series of existing machines you are in effect creating something new. • Therefore who ever is carrying out the work must ensure that the whole assembly complies with the Directive. • Regardless of the age of the machines. • If you are altering the function or performance of a machine or complex assembly you are again creating something new and must ensure that the Directive is complied with.
  • 4. Before we begin The Terminology Standard types: A-B1-B2-C Design architecture categories: B-1-2-3-4 (PL) Performance level: A-B-C-D-E (SIL ) safety integrity level : 1-2-3-4 (CCF) Common cause failure failures of different items, resulting from a single event, where these failures are not consequences of each other (SRP/CS) Safety-related part of a control system part of a control system that responds to safety-related input signals and generates safety- related output Signals (MTTFd ) Mean time to dangerous failure expectation of the mean time to dangerous failure (DC) Diagnostic coverage measure of the effectiveness of diagnostics
  • 5. Standards overview Safety circuit design On the basis of the risk assessment, the designer has to define the safety related control system. To achieve that, the designer will chose one of the two standards appropriate to the application: either standard EN/ISO 13849-1, which defines performance levels (PL) or standard EN/IEC 62061, which defines safety integrity levels (SIL) The table below gives relations between these two definitions To select the applicable standard, a common table in both standards gives indications: - d
  • 6. Standard EN/ISO 13849-1 • The Standard gives safety requirements for the design and integration of safety- related parts of control systems, including software design. • The Risk Graph helps to determine the required PL (Performance Level) of each safety function – S - Severity of injury > S1 Slight injury > S2 Serious or permanent injury or death – F - Frequency and / or exposure to a hazard > F1 Seldom to less often and / or short time > F2 Frequent to continuous and / or long time – P - Possibility of avoiding the hazard or limiting the harm > P1 Possible under specific conditions > P2 Scarcely possible
  • 7. Standard EN/IEC 62061 • Specific to the machine sector within the framework of EN/IEC 61508: – gives rules for the integration of safety-related electrical, electronic and electronic programmable control systems (SRECS) – does not specify the operating requirements of non-electrical control components in machine (ex.: hydraulic, pneumatic) • The probability of failure associated to the required SIL (Safety Integrity Level) depends on the frequency of usage of the safety function to be performed Safety of Machinery application EN/IEC 62061
  • 8. Introduction to Functional Safety The standard EN ISO 13849 A basic std EN ISO 12100 Fundamental notions, Design main principles EN 693 hydraulic Presses EN 692 Mechanical presses C specific class of machines EN 1088 Locking devices EN 953 Fixed and mobile protectors EN/ISO 13850:2006 Emergency Stop equipment EN 574 Bi-manual command devices B2 safety devices EN 1050 = EN/ISO 14121 Risk assessment EN 954-1 = ISO 13849-1:1999  EN ISO 13849 Safety of machinery Safety-related part of ctrl sys EN 60 204-1 Machines electrical equipment EN 294 and 999 Safety distances B1 specific safety aspect
  • 9. The 13849 standard Parts of machinery control systems that are assigned to provide safety functions are called safety-related parts of control systems (SRP/CS) and these can consist of hardware and software and can either be separate from the machine control system or an integral part of it. In addition to providing safety functions, SRP/CS can also provide operational functions (e.g. two-handed controls as a means of process initiation). The ability of safety-related parts of control systems to perform a safety function under foreseeable conditions They are allocated one of five levels, called performance levels (PL). These performance levels are defined in terms of probability of dangerous failure per hour . The probability of dangerous failure of the safety function depends on several factors, including hardware and software structure, the extent of fault detection mechanisms [diagnostic coverage (DC)], reliability of components [mean time to dangerous failure (MTTFd), common cause failure (CCF)], design process, operating stress, environmental conditions and operation procedures.
  • 12. Who is the designer who is the manufacturer? We are as we are upgrading the control system Is this a significant change to line 2 filler as defined in the directive? No as we are not changing the functionality technically but we are improving the existing controls . So re-CE Marking is not required
  • 13. Working example Electrical control system upgrade Note: Under PUWER assessment the electrical control system does not comply with BS EN 60204 Ref: General electrical requirements (Enacted in 17th edition).
  • 15. Integrity assessment First step Alternative PL Tools SISTEMA Software PL Calculation Tool SISTEMA is a software tool for the implementation of EN ISO 13849-1. Its use will greatly simplify the implementation of the standard. SISTEMA stands for "Safety Integrity Software Tool for the Evaluation of Machine Applications" It was developed by the BGIA in Germany and is free for use.
  • 16. Second step SAFETY FUNCTION DESIGN Performance Level Data: When configured correctly, the safety system can achieve a safety rating of PLd, Cat. 3 according to EN ISO 13849.1 2008. When modeled in SISTEMA, each safety E-stop string is treated as an individual safety function and can be modeled as follows. This diagram shows a single E-stop safety function. Calculations are based on 1 operation of the E-stop per month, with 12 operations per year; therefore 36 operations of contactors per year. The Diagnostic Coverage (Dcavg) is reduced to 60% for the E-stops because they are connected in series. SISTEMA File:
  • 17. Second step SAFETY FUNCTION DIAGRAM Process stop other equipment
  • 18. Third step PL FUNCTION VALIDATION OF DESIGN FOR THE SAFETY CONTROL SYSTEM
  • 19. Function design Validation (Refer to training module T2 for EOL Tool kit to undertake assessments and validation of circuit designs) First part Identifies the control systems required and their PL requirement
  • 20. Each section is taken individual and circuit function generated to achieve PL requirement
  • 21. Working example electrical drawings Emergency stop PONZ S4 PONZ S7
  • 22. Working example electrical drawings main drive inverter Safety Relay activation
  • 23. Working example Drive inverter Technical details
  • 24. Working example Drive inverter Technical details
  • 28. Old machinery in this context are machines which were placed on the market before the Machinery Directive came into force. The requirements of the directive were not applied to these machines. However, its application may become necessary should machines be extended, modified, modernized, etc. In such cases, assess- ment must be made for whether an essential change has occurred. Should this be the case, the requirements of the EC Machinery Directive apply to “old” machines in the same way as to new machinery. These requirements include the application of EN ISO 13849. Treatment of old machinery
  • 30. Design architecture and PL Overview PL
  • 31. Relationship Between Different Criteria • Relationship between Categories, DCavg, MTTFd and PL *In several application the realisation of performance level c by category 1 may not be sufficient. In this case a higher category e.g. 2 or 3 should be chosen.
  • 32. Working example Example 1: Emergency stop Safe Stop - Category B, PL b
  • 33. Design categories example Cat 2 Architecture EMERGENCY STOP, Category 2 single-channel,with feedback circuit
  • 34. Working example Example 2: Emergency stop with Safe Stop using safety relay - Category 3, PL d
  • 35. Design category example CAT 3 architecture EMERGENCY STOP, 2-channel, Category 3
  • 36. Working example Example 3:Emergency Stop of frequency converter with Safe Stop, Safety Relay and output contactor - Category 4, PL e
  • 37. Safety Chain Principle for Design Use devices that comply with safety standards Monitor & analyze the information Safety-oriented signal processing Catch the information Safeguarding to protect people from hazard Initializing & control of hazardous machine Emergency stop operations Stop the dangerous machine Signalling Disconnection and locking power supply Safe drive technology Safe signal transmission Safe connection & communication of functional units or segments
  • 38. Functional Safety Life Cycle Safety LifeSafety Life CycleCycle STEP 5STEP 5 MAINTAIN & IMPROVE SAFETY SYSTEM STEP 1STEP 1 RISK OR HAZARD ASSESSMENT STEP 4STEP 4 SAFETY SYSTEM INSTALLATION & VALIDATION STEP 2STEP 2 SAFETY SYSTEM FUNCTIONAL REQUIREMENTS (Conf STEP 3STEP 3 SAFETY SYSTEM DESIGN & VERIFICATION
  • 39. Other Modules in the S.Steele specialist technical Training module series T1 Introduction to EU Directive & Harmonization standards T2 EHSR Compliance & EOL Tool kit T3 Functional safety of control system design T4 Guarding fixed and movable T5 Electrical systems T6 EMC T7 Robots T8 Hydraulic T9 Pneumatic T10 HP Air systems T11 EC Marking Equipment END

Editor's Notes

  1. For combinations of several safety relevant parts into a common system the standard specifies the calculation of the resulting PL PL: from a to e, an associated probability of dangerous failures per hour
  2. the table only shows High Demand / Continuous mode (because Safety of Machinery only considers SIL 1 to 3 of this mode). The other mode (Low Demand) is normally a second column of this table for Low Demand mode with probability values x 10.000 (approx. nb of hours in a year!).
  3. DC – Diagnostic Coverage MTTFd – Mean Time To Failure (d- Dangerous) PL – Performance Level SIL – Safety Integrity Level
  4. Safety function comprises all parts of safety related electrical/electronic control system