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Safety Risk Assessment and Safety Evaluation Tool

Clearly DocumentedMachine Safety.From risk assessment to safety evaluation.

siemens.com/safety-integrated

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New machinery directiverequirementsThe aspect of functional safety mainlyfocuses on the correct function of amachines or systems control devicesand safeguards. The new requirementsof the 2006/42/EC machinery directive

address the subjects of risk assess-ment, requirements placed upon docu-mentation and suitable safety systems,conformity evaluation as well asmachine manufacturers outside theEuropean Union.

Recognition, control and consistentdocumentation of risksCompliance with the new machinery

directive and resulting export capabilityand liability security can be ensured

by application of the EN ISO 13849-1or EN 62061 standards. The safety ver-ification requested by both standardsis intended to prove the employedsafety solutions attainment of theSIL/PL value determined within thescope of risk assessment. A clearly

structured risk assessment thus repre-sents the basis for safety validation!

Consequently, risk assessment repre-sents the first step towards safemachine concepts already duringthe machines planning phase. Suchassessment should be carried out bycompetent qualified staff and incor-porated in the machines technical

documentation.

Safe machine concepts

without detours.The requirements of the new 2006/42/EC machinery directive on functional

safety which define the protection of humans, machines and production

goods came into effect on December 29, 2009. Machine manufacturers

and operators have to adjust to changed procedures and regulations in

order to ensure continued competitiveness, export capability and liabilitysecurity. These challenges can be perfectly mastered with the services

offered by the Siemens Safety Integrated portfolio: Safety Risk Assessment

Management and Safety Evaluation Tool.

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Relevant user standards

EN 62061:Safety of machinery functional safetyof electrical, electronic and programmablecontrol systems of machines.

EN ISO 13849-1:Safety of machinery safety-related partsof control systems. Part 1: General principlesfor design.

Protective measures for risk reductionwhich are described by means ofsafety functions can be derived fromrisk assessment. The safety functionssolution is then verified and evaluateduntil the safety integrity level requestedin the risk assessment is attained. In

this context, standard-compliant docu-mentation not only serves as proof,but also ensures consistent legal com-pliance and is indispensable for the CEdeclaration of conformity. Our SafetyIntegrated service portfolio supportsyou with the easy and reliable attain-ment of this target as follows:

1. Safety Risk AssessmentManagement:We offer competent support alreadyfrom the beginning of the planningphase. Within the scope of a one-daytraining and with the help of profes-sional documentation tools, our TV-

tested method for standard-compliantrisk assessment implementation inaccordance with EN ISO 14121-1resp. EN ISO 12100:2010 facilitatessafe machine concepts with minimumexpenditures.

2. Safety Evaluation Tool:Our TV-tested online tool supportsyou with the evaluation and docu-

mentation of your machines safetyfunctions.

Risk assessmentEvaluation and documentationof the safety function

Protective measuresfor risk reduction

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Maximum safety right from the start

with Safety Risk Assessment Management.

What are the requirements of the new machinery directive? How can these

requirements be utilized efficiently? Today, protective design measures are

often overdimensioned and cause unnecessary costs. The clearly structured

procedure of risk assessment provides reliability and reduces costs both

in terms of engineering and hardware. We offer comprehensive support

already at the beginning of the planning phase: Safety Risk Assessment

Management the TV-tested method for standard-compliant risk assessment

implementation in accordance with EN ISO 14121-1 resp. EN ISO 12100:2010.

Risk assessmentEvaluation anddocumentation ofthe safety function


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As early as during the planning phase,

Safety Risk Assessment Managementprovides perfect support with regardto the machinery directives require-ments. Your advantage: Identifieddesign measures for risk reduction canalready be incorporated during theconstruction phase doing away withcost-intensive and laborious reworkson an already constructed machine.

Advantages of the method:

Clear information on each stepand clear instructions regardingmachine protection on the basisof design measures or other mea-sures, right down to the definitionof safety functions of technicalsafeguards in accordance with

EN 62061 or EN ISO 13849-1 without additional tools.

This structured approach of riskassessment offers advantages forall staff members from construc-tion (mechanics, electrics, hydrau-lics, pneumatics) and engineeringinvolved in machine production.

Integrated support with Safety Risk

Assessment ManagementSafety Risk Assessment Managementcomprises a comprehensive package,including instructions, templates andcheck lists for the preparation of aseamless, clearly structured and cor-respondingly comprehendible docu-mentation. With Safety Risk AssessmentManagement, you will benefit from

a thorough research of directives andstandards as well as from a clear methodfor risk assessment jointly developedwith the TV (German Technical Inspec-torate). All it takes is a one-day training!Subsequent TV acceptance can bearranged for rapidly and effortlesslyupon request.

SITRAIN course: ST-RAMRisk Assessment Management method for standard-compliant riskassessment implementation inaccordance with EN ISO 14121-1resp. EN ISO 12100:2010

The target of this one-day seminar aimsat making the process of risk assessment

as necessary step for CE marking trans-parent and comprehendible on the basisof a specific method. Seminar partici-pants will be introduced to the methodof risk assessment in accordance withEN ISO 14121-1 resp. EN ISO 12100:2010on the basis of pre-fabricated templateswith the help of a real example.

Further information is available at:

www.siemens.com/sitrain-safetyintegrated

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A. Description of the machine

B. Definition of machine areas and hazard zones

C. Risk assessment

D. Risk-reducing protective measures based on the realizationof safety functions

E. Validation of safety functions: including evaluation anddocumentation with the Safety Evaluation Tool

The result:

Comprehendible documentation of a machines risk assessment

Safe machine concepts

CE conformity

Correct application of the machinery directive and new standards

Advantages offered by the TV-tested method

Easy implementation thanks to: multiple usage of text blocks for further risk assessments of similar machines

as well as for technical documentation uniform terms for all involved departments

Time and cost savings

Consistent legal compliance through application of harmonized standards

Step-by-step approach for safemachine concepts:



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The documents provide excel-

lent support as they offer sound

readability and comprehensi-

bility thanks to the definition

and consistent use of uniform

terms.

GS-Steuerungstechnik GmbH benefitsfrom Safety Risk Assessment Management.

GS-Steuerungstechnik GmbH is aninnovative company in the field ofcontrol technology which has amongstothers specialized in the retrofittingand production of friction welding andspecial-purpose machines. The com-

pany opted for Safety Risk AssessmentManagement by Siemens for the reli-able risk assessment of its new frictionwelding system and was able toimplement the assessment autono-mously and with minimum timeexpenditures after a brief introductionto the method.

The easily and effortlessly applicablerisk assessment method supported ajoint understanding of the safety-tech-nical correlations of mechanics,hydraulics and electrics. This is under-lined by the following compliment

made by GS-Steuerungstechnik GmbH:Thank you for your support! The docu-ments provide excellent support asthey offer sound readability and com-prehensibility thanks to the definitionand consistent use of uniform terms.

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From risk assessment

to the result report.

The trainings and tools offered by our Safety Integrated portfolio

support you with the easy, rapid and safe conversion to the new

machinery directive. The example below demonstrates the successful

risk assessment implementation on the basis of Safety Risk Assessment

Management and the evaluation documentation of your machines

safety concepts. Our Safety Evaluation Tool supports you on the way

to standard-compliant machine documentation.



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Procedure

Four hazard areas were determinedfor a machine on the basis of risk

assessment:

1. Access to the machine area2. Area around the handling machine

during maintenance3. Material discharge4. Stopping of the conveyor belt5. Stopping of the complete system

For protection of the hazard zones,four safety functions with specificrequirements in terms of safety integ-rity (e.g. SIL 2 or PL d) have to beimplemented as risk-reducing mea-sures. These measures are analyzed,evaluated, modified within the scopeof an iterative process if required,evaluated anew and then realized.

Technical protective measures

The following solutions were deter-mined as result:

1. Protective fence with door monitoring2. Protection during zone-dependent

maintenance with slow speed or stop3. Non-contact monitoring of material

discharge4. EMERGENCY-STOP on the conveyor

belt5. Global EMERGENCY-STOP

Documentation

For safety verification in the machinedocumentation, each safety functionhas to be evaluated with the selectedcomponents in accordance with manu-facturer specifications. Application ofthe EN 62061 or EN ISO 13849-1 stan-dards facilitates such evaluation in order

to attain compliance with the machinerydirective. The Safety Evaluation Tooloffers valuable support with thisprocess.

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Standard-compliant machinedocumentation with the SafetyEvaluation Tool step-by-step.

The Safety Evaluation Tool for the EN 62061 and EN ISO 13849-1 standards

takes you to your goal directly. This TV-tested online tool from the Safety

Integrated portfolio by Siemens facilitates the fast and reliable evaluation

of your machines safety functions. As a result, you are provided with a

standard-compliant report which can be integrated in the documentation

as proof of safety.



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Safety Evaluation Tool advantages

at a glanceSafety regarding the standardsapplication: automatic calculationon the basis of currently applicablestandards

Rapid result: standard-compliantreport

TV-tested tool

Reduced time expenditures for safetyfunction evaluation

Rapid access to current product data

Comfortable archiving: Projects canbe saved and called up as required

Rapid and easy handling:comprehensive, pre-defined examplelibraries

Free use of the online tool*Global service and support(* only the usual costs for Internet access accrue)

The Safety Evaluation Tool forms part of Safety Integrated, the intelligentsafety solution by Siemens with a comprehensive product portfolio. Ourcertified safety technology complies with all relevant standards and isalready incorporated in the Safety Evaluation Tool.

Further information on how to realize increased safety and productivity isavailable at:

www.siemens.com/safety-integrated

Safe machine concepts without

any detoursWith the Safety Evaluation Tool, youopt for the easy way for your machinessafety verification as the online toolguides the user through the evaluationprocess step-by-step from specifica-tion of the safety systems structure tocomponent selection down to determi-nation of the attained safety integrity

level (SIL/PL).

When starting a new project, the safetyzones are analyzed initially, after whichthe safety functions are created (step 1to 3). In the next step, subsystems arecreated and filled with data (step 4).After evaluation of the overall result,the final report is output which pro-vides clear status information at alltimes (step 5 and 6).

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Definition of a safety function

e.g. safety function zone-dependentmaintenance

Key switch is set to maintenance.

Modular safety system generatessignal for reduced speed (safelylimited speed) of the frequencyconverter

Release of the position switchs doortumbler and opening of the door

Selection of the standard to be usedfor calculation

EN 62061 or

EN ISO 13849-1

Step 2Step 1

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Creation of subsystems or SRP/CS,detection, evaluation and reaction

Data entry:Product selection from database

Step 4

Description of the safety function

The safety function zone-dependentmaintenance consists of the subsystems

detection (position switch), evaluation(modular safety system) and reaction(drive).

Entry of the required PL or SIL

Step 3

Result:Safety Integrity Level (SIL) or

Performance Level (PL) andPFHD of the subsystem orSRP/CS

Position Modular SINAMICSswitch safety system S120

Detection Evaluation Responding

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Determination of the overall result Generation of result report formachine documentation

Step 5 Step 6

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Siemens supports you!

As partner for all safety issues, we not only offercorresponding safety-related and certified productsand systems, but also consistently provide you withup-to-date know-how of international standards andregulations. We offer a comprehensive range of train-ings and services for machine manufacturers andsystem operators throughout the entire life cycle ofsafety-technical systems and machines.

You require furtherinformation?

More detailed information is availablevia the following links:

Training/standards training: SITRAIN SafetyContact: www.siemens.com/sitrain-safetyintegrated

Information on Safety Integrated:www.siemens.com/safety-integrated

Service & Support:www.support.automation.siemens.com

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Siemens AGIndustry SectorIndustry Automation& Drive TechnologiesP.O. Box 23 5590713 FUERTHGERMANYwww.siemens.com/safety-integrated

Subject to change without prior notice 11/12Order No. E20001-A250-M103-V1-7600Dispo 27610MI.CE.XX.XX03.52.2.01 WS 10112.Printed in Germany Siemens AG 2011

The information provided in this brochurecontains merely general descriptions or char-acteristics of performance which in actualcase of use do not always apply as describedor which may change as a result of further

development of the products. An obligationto provide the respective characteristics shallonly exist if expressly agreed in the termsof contract. All product designations may betrademarks or product names of Siemens AGor supplier companies whose use by thirdparties for their own purposes could violatethe rights of the owners.

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