Technical Seminar Safety Rules For Different Zones in Industrial Automation Manoranjan Sahoo EI...

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Safety Rules For Different Zones in Industrial Automation

Manoranjan Sahoo EI 200117259


Presented by Manoranjan Sahoo EI200117259

Under the guidance of Mr. Bhawani Shankar Pattnaik

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Safety is a situation, whereby the risk is not greater than the limit risk.

Risk is a combination of the probability and the degree of the possible injury or damage to health in a hazardous situation.

Safety is relative.

There is no such thing as 100% safety.

INTRODUCTION

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Danger: The risk is greater than the limit risk.Safety: The risk is not greater than the limit risk.Limit risk: The maximum acceptable level of risk.Residual risk: Risk remaining after safety measures has taken.

The Margin Between Danger and Safety

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Why Safety?

Prevention of accidents

Protection in the workplace.

Cost effective.

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DIFFERENT SAFETY STANDARDS

ANSI:- American National Standards Institute. IEC:- International Electrotechnical Commission. DIN:- Deutsches Institute of NormungOSHA:- Occupational Safety and Health Administration EU:- European economic Union (EN-standards)

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SAFETY ZONES

Safety Integrity

Level

Probability of failure on demand

1 >=10^-5 to <10^-4

2 >=10^-4 to <10^-3

3 >=10^-3 to <10^-2

4 >=10^-2 to <10^-1

Relation between SIL and PFD

Relation between SIL and SC

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SAFETY RULES

Flow chart for the iterative process to achieve safety

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Determination of the Limits of Machinery All phases of machinery life The limits of machinery including the intended use The full range of foreseeable uses of the machinery The anticipated level of training, experience, and ability of the user Exposure of other persons to the hazards of the machinery Hazard Identification Risk Estimation

Risk analysis:

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Risk Evaluation and Reduction

Safe machinery design

Protection measures for the risks that can’t be eliminated

Inform users of the residual risks

Information, instruction, training and supervision

Use of Personal Protection Equipment

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Area Guarding

Switch off power when a person enters the hazard area Prevent switching on power when a person is in the hazard area.

Trip and presence sensing device Trip and Area guarding

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Choice of Protective Measures

1. Preventing access during dangerous motion Fixed Guards Movable Guards Two-Hand Controls 2. Preventing dangerous motion during access. Photoelectric Light Curtains Pressure Sensitive Safety Mats Pressure Sensitive Edges

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Fixed guard Movable guard

Two Hand control

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Pressure Sensitive Edge

Pressure Sensitive Safety Mat Photoelectric Light Curtain

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Emergency Stops

Cable Pull Switches Telescopic Trip Switches

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Safety Light Curtains

Safety light curtains fall into three product families

1. Point of Operation Control 2. Area Access Control

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Safety Light Curtains

3. Perimeter Access Control

Function Advantages Greater productivity Ergonomically sound Frequent and easy access

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Blanking- Fixed and Floating

Fixed Blanking Floating blanking

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Muting

The muting conditions defined in IEC 61508:a. Muting is only permitted to be activated during the time span of the working cycleb. Muting must be performed automatically. c. Muting must not depend on a single electrical signal.d. Muting must not depend completely on software signals.e. The muting signals, if they occur as part of an invalid combination, must not permit any muting state. f. The muting state is removed immediately after the pallet has passed through

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Muting

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How to choose the device 3 characteristics of a device:

Resolution The height of the protected area The safety distance

Resolution visualization

R = I + d R = ResolutionI = Inter-axis distanced = Diameter

Resolution for body Protection

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The height of the protected area

HCA = HSA+2I WhereHCA = Height of the controlled areaHSA = Height of the sensitive areaI = Inter Axis distance

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The safety distance

OSHA Formula: Ds = 63 X TS where Ds= Safety Distance 63 = Recommended hand speed in in/sec

TS = Total stop time in Sec ANSI Formula: Ds = K x (Ts + Tc + Tr + Tbm) + Dpf Ds = The minimum safe distance K = 63 (hand speed in in/sec) Ts = Stopping time of machine, in seconds Tc = Control circuit response time in seconds Tr = Light curtain response time Tbm = Response time of a brake monitor Dpf = Depth penetration factor EN 1050 Formula:

S = (K x T) + C K = 1600mm/sec assumed operator speed T = The overall stopping time of the system C = Depth of penetration S = Safety distance

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CONCLUSION

High efficiency is required High accuracy is required Complexity increases Terrorism increases Safety is required

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Technical Seminar Safety Rules For Different Zones in Industrial Automation Manoranjan Sahoo EI...

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