Safety Assessment

Introduction to General Safety:

Where appropriate, it is intended that this equipment complies by the guidelines presented in

AS4024 - Safety of Machinery [1]
BS EN415-7:2006 - Safety of Packaging Machinery [2]
ISO 13849:2006 Safety-Related Parts [3]
and/or IEC 62061 Safety of Machinery [4]

The equipment supplied is fully automatic. With the exception of conveyors, operation and maintenance staff are only required to be exposed to moving or hazardous parts when the machine has been de-energized. For this reason, from a guarding and safety perspective, the P715 Semi-Automatic Cartoning Machine will be treated as a single safety cell. The proposed guarding is illustrated in Figure.2. Red lines represent fixed guarding solutions; associated entry points (i.e., doors) will be protected using interlock switches and are shown in yellow.

Figure.2 Guarding Proposal

1. Electrical and Control Systems

Bector Automation RML India Pvt Ltd representatives have conducted a Risk Assessment to determine the potential hazards and risks present in the proposed machinery. The panel is provided with safety for LOTO (Lock out and Tag Out). This has led to a document which systematically evaluates each area of the machine by scoring each potential hazard with a hazard rating number, whereby the highest hazard rating number is expected to present the most severe risk.

The machinery designed is intended to be a single safety cell, so the highest scoring hazard became the driving factor for the level of protection required in this safety cell, for which the required performance levels (PL) for the safety functions of safety related components was identified to be PL(d).

2. General requirements

As mentioned previously, with the exception of conveyors, operation and maintenance staff are separated from the moving and hazardous parts of the machine by the guard structure when the machine is energized. Access to the internal parts of the machine can only be possible when the machine has been de-energized, and the machine is deemed to be in a “Safe state”. For this reason, the safety system shall be designed and implemented to serve the sole function of de-energizing all moving or hazardous equipment when a non "Safe State" is detected.

With reference to Figure.2, and the required levels of protection (SIL 2 and PL(d)), the components required to make the safety control system will be a safety controller, safety contactors, emergency stops, door switches, photoelectric sensors and a safety air service unit. The devices within the safety control system are expected to respond, and the safety system switch, to a safe state within 0.8 seconds of any potential fault detection or safety function demand. Maximum fault detection time (i.e., determining the difference between device fault or safety function actuation) should be no more than 3 seconds. These values are determined from experience with similar machinery.

Considerations during the design phase in respect to the operating environment of the machinery were made

The machinery due to its function and operating environment will not be subject to shocks or vibrations.
Electromagnetic compatibility is adhered to by installation of electrical components undertaken by qualified personnel.
The machine is designed for a non-wash down food packing environment.
Material selection and professional design solutions have been implemented to ensure mechanical durability.
It is expected the machine will be operating in ambient room temperature.

Correct maintenance of machinery componentry, both mechanical and electrical is outlined in the machinery manual that is supplied with the p715 Semi-Automatic Cartoning Machine.

Above and beyond the manufacture certifications of the devices used, correct installation and implementation of devices must be adhered too. Fault detection should cover, but is not limited too

Cross circuits
Short circuits
Open circuits
Cross terminals

2.1 HAZOP

HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.

Please refer the below attachment for HAZOP Document

16339- Risk Assessment

2.2 Safety Relay

Note: Click on the Image for the Component Manual

A safety Relay will be used to operate the safety system. The safety controller will provide an interface for all the safety control devices. If any of the devices show faults or are in an un-safe state, the safety controller will proceed to remove all energy from the machine. Manufacturer specifications make the chosen safety module suitable for the current situation in terms of the levels of protection required. Table.3 below shows the safety Relay components.

Table.3: Safety Relay part data

Description

Part No.

Quantity

Safety Relay

SRB 301MC

2.3 Safety Contactors

Note: Click on the Image for the Component Manual

Safety contactors are used to isolate power to specific devices within the machine. The safety contactors work in conjunction with the safety controller, so that when an un-safe state is detected by the safety controller, the safety contactors work to isolate all relevant devices to allow the machine to reach a safe state. Below are the part details and a reliability block diagram (RBD) of the safety contactors to demonstrate the required architecture.

Figure.5: Safety contactor RBD

Table.4: Safety contactor part data

Description

Part No.

Quantity

Schneider Safety Contactors

LC1D18BD

2.4 Emergency Stops

Emergency stops are located in the most practical places around the machine. Practical places are often driven by such factors as

At control points (i.e., below the Operator panel)
In areas to ensure that no matter where an operation staff may be located, they can easily get to an emergency stop position

Direct guidelines are also used to place emergency stops such as that specified in BS EN 415 [2]. For example, these are relating to distances from conveyor guard tunnel openings and distances between emergency stops. The safety function of the emergency stop is to divert the safety system to an unsafe state when activated and in turn completely de-energise all machinery. Below are the part details and a reliability block diagram of the emergency stops to demonstrate the required architecture.

Figure.6: Emergency stops RBD

Table.5: Emergency stops part data

Description

Part No.

Quantity

Sick E-Stop

ES21-SA10F1

2.5 Safety Monitored Air Service Unit

A number of the moving parts within the machinery supplied are pneumatically operated. Actuation of these pneumatic devices are electrical, however the energy associated with the mechanical movements is pneumatic. As mentioned previously, to ensure complete de-energizing of the equipment, all pneumatic devices must have their energy removed. A safety monitored dump valve is expected to achieve this if signaled to do so by the safety controller. Below are the part details and a reliability block diagram of the safety dump valve to demonstrate the required architecture.

Figure.9: Air service unit RBD

Table.6: Safety Relay part data

Description

Part No.

Quantity

Filter Regulator

MS4-LFR-1/4-D7-C-R-M-AS

3.PERSONAL SAFETY

As part of the commissioning programme, an “on machine” training course is carried out by BAR India Pvt. Ltd. Training is split into 2 categories:

Operator and Maintenance Training - for personnel who will operate or maintain the machine. Only authorised and fully trained personnel are to operate or maintain this machine. Table 2.1 below records the operators and maintenance personnel who have completed this training.
Technical Support Training - for personnel who will provide technical support for the machine. Only authorised and fully trained personnel are to give technical support for this machine. Table 2.2 below records the technical personnel who have completed this training.

It is the client’s responsibility to perform all operator, maintenance and technical support training after the takeover certificate has been issued.

Please refer the below Training Certificate.

Training Certificate