Schaalbare veiligheidsoplossingen

Schaalbare veiligheidsoplossingen

Welkom bij deze presentatie/demonstratie Stephen Podevyn Business Manager Safety FS Engineer (TÜV Rheinland, ID No 6230 /13, Machinery & Process)

Hans Zuur Commercial Engineer Safety FS Tech (TÜV Rheinland, ID No # 253/15, Machinery)

Rockwell Automation

- Diversiteit van produkten - Aantal I/O’s - Veiligheidsdiensten Specialist in Automatisatie met integratie van veiligheid = performance

Market Leading Safety Products & Solutions Rockwell Automation Safety Market Leaders

Machine Safety

Process Safety Kent u het verschil tussen proces- en machineveiligheid?

Safety Assessment and Mitigation Services

Geintegreerde veiligheidsoplossingen


Arbeidsmiddelen- & Machine- richtlijn Kaderrichtlijn 89/391/CE

Machinerichtlijn

2006/42/EC

Arbeidsmiddelen richtlijn

Normen

2009/104/EC

Arbeidsmiddelen- & Machine- richtlijn

Functional Safety Management

Ontwerp / doelstelling Gevarenanalyse & Risico-inschatting

ANALYSE

Veiligheidseisen en specificaties

Conceptioneel ontwerp Gedetailleerd ontwerp

REALISATIE

Installatie, validering oplevering In dienst & onderhoud Uitdienstname

Modificatie

In bedrijf

De te volgen stappen Stap 5 Validatie, onderhoud, Verbeteren en opleidingen

Stap 1 Risico inventarisatie en evaluatie

Safety life Cycle

Stap 4 Installatie van het veiligheidssysteem

Stap 2 Eisen van het functioneel veiligheidssysteem Stap 3 Veiligheidssysteem Ontwerp & Verificatie

Heeft u al deze safety life cycle gevolgd ? 9

Veiligheidsdiensten Stap 5 Validatie, onderhoud, Verbeteren en opleidingen

• • • • •

Wereldwijde dekking van consultants en ingenieurs op het terrein van machine veiligheid. Het Team gebruikt wereldwijd dezelfde methode, de S/W tool is meertalig. Ze zijn beschikbaar om onze klanten te helpen op verschillende vlakken en fases van het safety-traject. Werken samen met onze locale projectteams voor het ontwerp en verificatie Validatie van de oplossing na installatie

Stap 1 Risico inventarisatie en evaluatie .

Stap 2 Eisen van het functioneel veiligheidssysteem

Verzekeren van conformiteit met de normen en richtlijnen. 10

Risicoanalyse Stap 5 Validatie, onderhoud, Verbeteren en opleidingen


Safety life Cycle



11

Het te volgen proces Bepaal de grenzen van de machine

Kent u het verschil tussen een gevaar en een risico ?

Identificatie van het risico

Volgend risico of gevaar

Inschatting van het risico

OK Evaluatie van het risico Niet aanvaarbaar

Reductie van het risico

Tolereerbaar risico

Voorbeeld van een risicoanalyse rapport Vergadering met het veiligheidsteam van de klant : (bedienaar, onderhoud, productie, veiligheidsdienst.)

- Verklaring van het rapport HRN methode / risico - Compromis - Taken - Gewoontes - Modes van operatie - Historiek - Noodzakelijke toegangen - Etc..

Functionele veiligheidseisen Stap 5 Validatie, onderhoud, Verbeteren en opleidingen


Safety life Cycle



14

Hiërarchie van de te volgen maatregelen voor het reduceren van risico’s Hiërarchie van de te volgen maatregelen Maatregelen in ontwerp fase

Vergadering met het veiligheidsteam van de klant - Hiërarchie van de risico’s Vaste afschermingen - types produkten - oplossingen voor het onderbreken van de energie - mechaniche Beweegbare afschermingen met oplossingen bewakingBepalen van het totale veiligheidsconcept

Meest

efficiënt

Vastleggen van het verificatie & validatie plan (stap5)

Sensibiliseren, opleiden en procedures (administratief)

Persoonlijke beschermingsmiddelen

Minst efficiënt

Ontwerp en installatie Stap 5 Validatie, onderhoud, Verbeteren en opleidingen


Safety life Cycle



16

Ontwerp & Installatie

Installeren van het veiligheidsconcept met een locale partner met hulp van Rockwell Automation.


Stap 3 Veiligheidssysteem Ontwerp & Verificatie

17

Validatie Stap 5 Validatie, onderhoud, Verbeteren en opleidingen


Safety life Cycle



18

Validatie van het veiligheidssysteem Validatie De validatie van het veiligheidssysteem bewijst dat het systeem voldoet aan de eisen die gesteld zijn bij het ontwerp.

Verificatie van de architectuur

Test protocol Validatie ter plaatse

Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

Rapport

19

Partner voor veiligheid

 Wereldwijde Fabrikant  Marktleider in verschilllende landen  #1 of 2 in alle domeinen van hun activiteiten

Het te volgen proces Audit arbeidmiddelen

Audit

Gebruik van arbeidsmiddelen geleverd door een consultant van Rockwell Automation

Prioritiseer Stap 5 Validatie, onderhoud, Verbeteren en opleidingen


Kleine update (klant)

Safety life Cycle Stap 4 Installatie van het veiligheidssysteem Geen andere acties

Stap 1 : gebruik van arbeidsmiddelen

Stap 3 Veiligheidssysteem Ontwerp & Verificatie

Stap 2 Eisen van het functioneel veiligheidssysteem

Ja – Prioritiseer  Welke machines of processen hebben incidenten of bijna ongevallen gehad in het verleden ?

 Welke zijn de oudste machines, welke gaan we updaten , welke gaan we vervangen ?  Kwalificatie Audit

Voorbeeld van rapport : Arbeidsmiddelen

Het te volgen proces Audit arbeidsmiddelen

Audit


Risicoanalyse (Rockwell Automation)

Audit

Kleine updates (klant)


Geen andere acties


Stap 2 : Risico analyse Prioritaire machines

Voorbeeld rapport van een risicoanalyse

Het te volgen proces Audit arbeidmiddelen

Audit




Audit

SRS (Rockwell Automation)

Ontwikkeling van het SRS


Audit

Installatie (Rockwell Automation)

Installatie (3rd Party)

Geen andere acties


Validatie (Rockwell Automation)


Stap 3 : Definieren van de eisen, specificaties, uitvoering van het project, verificatie & validatie

Veiligheidsproject – Creatie SRS





Veiligheidsproject – Creatie SRS Audit arbeidmiddelen

Audit




Audit

SRS (Rockwell Automation)

Ontwikkeling van het SRS


Audit

Installatie (Rockwell Automation)

Installattie (3rd Party)

Geen andere acties


Validation (Rockwell Automation)


Stap 3 : Definiering van de eisen, specificaties, uitvoering van het project, verificatie & validatie

Safety resource

1. Safebook

Kant- en klare veiligheidapplicaties

Kant- en klare veiligheidapplicaties http://marketing.rockwellautomation.com/safety/en/safety_functions

Opleidingen in veiligheid  Competentie niveau 1 : intern & autodidactische opleiding (NON RA)  Competentie niveau 2: Veiligheidseminar (1dag)  Competentie niveau 3 : 

TÜV Rheinland FS Technician (3 days with exam) (Engels)



Programmatie veiligheidscontroller GuardLogix (2 dagen )



SISTEMA Validatie (1 dag)

 Competentie Master (Engels) 

TÜV Rheinland FS Engineer twee delen: 

TÜV-1 pre-course,(3 days)



TÜV-2 course with exam (4 days)

Agenda Typical Safety Functions

Scalable Safety Solutions GuardLogix Safety Accelerator Tool Kit

Safe Motion


Validatie Stap 5 Validatie, onderhoud, Verbeteren en opleidingen


Safety life Cycle



Identificeren van veiligheidsfuncties begint met de risicoanalyse. 41

Typische veiligheidsfunctie

Veiligheidsfuncties ISO13849-1 (Table 8)  Safety Related Stop Initiated by a Safe Guard

 Emergency Stop Function (EStops Pull Chords)  Safety Gate Monitoring & Locking (Safety Switches and Interlock)

 Presence Detection (Light Curtains & Safety Mats)  Safe Torque Off ( Contactors and Safety Enabled Drives)  Safe Limited Speed  Safe Max Speed  Safe Direction.

IEC 61800-5-2 Funtional Safety of Power Drive Systems

Eenvoudige veiligheidsfunctie

Input element

Logisch element

Output element

Safety interlock switches

Presence sensing safety devices

• •

•

Detection of a person or moving object Passive safety interlocking option - no physical action required between the devices and the operator/object Devices include: – – – – –

Safety light curtains Safety laser scanners Safety camera Pressure sensitive mats Pressure sensitive edging

•

•

Physical Interlocking of guard doors or systems Opening the guard door activated the interlocks Non-contact or physical interlocking versions are available Versions to lock guard door closed available Key exchange systems

•

Devices include:

• • •

– – – – – –

Tongue operated interlocks Hinge operated interlocks Guard locking interlocks Non-contact interlocks Safety Limit Switches Trapped key systems

Emergency stop & trip devices

• • •

Devices used in the event of an emergency to stop a hazard Versions with push-button or rope (cable) pull actuation Devices include: – –

Emergency stop buttons Cable pull safety switches

Operator interface

• • •

Devices used to safety interact with applications Physical actuation of capacitive actuation Devices include: – –

Enabling grip switches Two hand controls

SC300 Eenvoudige installatie werkt in 2-D In een opening van max 1.5 m op 1.5 m Wordt in een hoek van de te bewaken opening geinstalleerd

Aan de overzijde kleeft u de reflecterende tape

Druk de leerknop in of gebruik een externe schakelaar Kijk de beveiligde zone na met de meegeleverde “stylus”

SC300 veiligheidscamera 46

GuardShield Safe 4

Geïntegreerde laser uitlijning  De uitlijning van onze lichtgordijnen is heel eenvoudig dmv de geïntegreerde lasers  In zowel de zender als de ontvanger is een klasse 2 laser ingebouwd  Door een simpele aanraking worden deze geactiveerd.  Na 5 minuten worden ze automatisch uitgezet

Praktisch in het gebruik

Laser scanner  High Performance and full featured      

Single Field Set, (One safety and one or two warning fields) Selectable resolutions of 30mm, 40mm, 50mm, 70mm, 150mm 270⁰ scanning angle up to 3 metre safety field, 8 metre warning field EDM and Restart Interlock Category 3, SIL 2, PLd safety ratings

Modern Compact Design 

102mm x 116mm x 105mm package  M12 8-pin connector

Noodstop Self-monitoring contact 1

.1

.2

X = geslotenO = Open

2

3

X

O

O

Noodstop uitgetrokken NC en NOEM contact gesloten

Noodstop ingedrukt NC contact open

Noodstop gedemonteerd NOEM contact open

Sensaguard SIL3 – Ple - Cat 4 PFHD = 1,12x10-9

RFID (non contact)

Sensaguard Sensaguard kan in serie gezet worden zonder verlies van Plr of SIL Opgelet voor de reactietijd

Veiligheidsrelais

51

RFID Guardlock DeurslotenTLSZ en 440G-LZ SIL3 ; Ple ; Cat 4

RFID Deurslot) RFID tag

Metalen bout die in een metalen opening schuift

QR code die u de installatie handleiding ophaalt

LEDs (aan beide zijden)

Wereldweide goedkeuringen

Volledig dichte constructie (IP69k)

Multifunctional Access Box (MAB)  Integrated solution for Full Body Access applications 

Integrated Door Handle, Guard Locking Switch and Access Control and Indicator Panel

 Compliance with latest standards 

PLe and SIL 3

 Unique design allows for easy installation and use 

IP54, Robust handle and lock mounts on 45mm profiles



Four LEDs for detailed system status & diagnostics

 Options and accessories provide versatility to meet every application 

Multiple Push button, Indicators, E-Stop, Escape Release, and place for use of a safety lock

 CIP Safety add on Module scheduled for 2016 53

Producten Safety logic controllers Monitoring safety relays

• • • •

Dual channel monitoring of the safety systems Comprehensive range for your application Single function, modular of configurable versions Devices include: – – – –

54

MSR100 - Single function safety relays MSR200 – Modular safety relay system MSR300 – Configurable safety relay system Guard Master Safety Relay

Programmable safety controllers

• • •

• •

Packaged safety controller (SIL3) Programmable using RSNetWorx software CIP safety over DeviceNet and optional EtherNet/IP version for diagnostic comms Communicates and controls safety I/O Devices include: – –

SmartGuard 600 440C-CR30

Safety I/O devices

Integrated safety controllers

• • • • •

GuardLogix integrated safety controller (SIL3) for ControlLogix Standard and safety control in one platform CIP safety over EtherNet/IP or DeviceNet Communicates and controls safety I/O Devices include: – –

GuardLogix PAC Compact GuardLogix

• • • •

Safety rated I/Os EtherNet/IP or DeviceNet connectivity Use with programmable and integrated safety controllers Devices include: – – –

CompactBlock GuardI/O ArmorBlock GuardI/O POINT GuardI/O

Producten Safety actuators PowerFlex AC drives

Safety Contactors

•

•

Mechanically linked, positively guided contacts Feedback circuit for safety integrity Range of power ratings

•

Devices include:

•

– – – –

100S Safety Contactors 700S Safety Contactors 109S Safety Contactors 700 HPS Safety Relay

•

•

PowerFlex AC drives with optional integrated safety functions Advanced safety functions in PowerFlex 750 series AC drives May replace the need for safety contactors Remove torque without powering down machine Restart machines faster

•

Devices include:

• • •

– – – – – 55

PowerFlex 40P PowerFlex 70 PowerFlex 700 S/H PowerFlex 755/753 PowerFlex 525

Kinetix Integrated motion

•

•

Kinetix 6000 with optional integrated safety functions Safe Torque Off and advanced safety CIP Safety & CIP Motion Remove torque without powering down machine Restart machines faster

•

Devices include:

• • •

– – – – – – –

Kinetix 6000 Kinetix 7000 Kinetix 6500 Kinetix 6200 Kinetix 5500 Kinetix 350 Kinetix 300

Benefits of S.A.B Hazard or Risk Assessment

S.A.B

Functional Requirements

Available as a free download from the Rockwell Automation website. It guides manufacturers through the safety-system design process by providing options for layout, safety performance level (PL) analysis based on ISO 13849-1 using IFA’s SISTEMA tool, and product selection using Allen-Bradley safetyautomation products.

SISTEMA

Bill of Material

Project Layout

SISTEMA Validation

SAB - Safety Automation Builder Patent Pending

Complete Safety System Layout

Demonstration Time

Performance Level Verification Report

Complete Bill of Material



Safe Motion

Machine Safety

10+

Connected Enterprise across all platforms Integrated Safety

9

GuardLogix

7

CompactLogix

5

440C-CR30 with 2080-ENET

ControlLogix

3

440C-CR30

GSR with GSR-ENET

1

Safety Complexity (# zones)

Compact GuardLogix

Premier Integration

Connected Components Micro 800

L1 to L3

L4 to L7

Control Complexity

Safety scales and data flows in all architectures

Safety Logic Portfolio GuardLogix L7xS

5370 Compact Guardlogix L3

Ethernet Plug-in

440C-CR30 22pt GSR Safety Relay Optical Bus System

MSR / GSR Relay

GSR- EIP

Compact GuardLogix L4x

440 ENETR Guardmaster® EtherNet/IP™ Network Interface

 Connectivity for Guardmaster Safety Relays to Ethernet Networks Up to six GSRs supported by a single network interface



IRLight Transmit

IRLight Receive

Optical Bus System Ethernet

Optical Bus System

 GSRs communicate seamlessly when mounted within 5mm of each other through the optical bus system 

No need for extra wires or connectors

Flexibility 2-port embedded switch

Ring Topology

Linear Topology

 2-port embedded switch supports linear, star, and ring EtherNet/IP network topology:  Linear topologies save on the costs of cabling and a centralized switch  Ring topologies offer these benefits and high availability

Guardmaster® 440C-CR30 Software Configurable Safety Relay

Guardmaster 440C-CR30 Software Configurable Safety Relay

 CR30 Software Configurable Safety for machine safety applications  PLe and SIL 3  22 Safety I/O

 Supports expanded standard I/O via plug-in  Configured using free Connected Components Workbench™ software  Intuitive software simplifies configuration

Guardmaster 440C-CR30 Software Configurable Safety Relay  Easy to Use: 

Innovative rapid configuration editor

 Single Wire Safety Support: 

A single wire to expand safety I/O

 2080 Plug-in Support: 

Expansion of standard I/O

 Serial Port for Diagnostics 

Keeps safety simple, separate and flexible

PanelView Component or Micro800

What’s New in Release 8 440C-ENET: Supported Topologies

 System Integration with Logix controllers  with AOP version 2.00 (Coming in May 2015)

Control Level

Information Level

Single Software Package!

 Design Software: Add-on Profile in Studio 5k v20 or later

Design Software

 Controller: Logix5000 controller, Controller

firmware revision 20 or later

Device Level

 HMI: PanelView Plus HMI

 440C-CR30: Revision 8 or later 440C-CR30

firmware and 440C-ENET plug-in

Product Information Unique Value

 Premier Integration with Logix control systems: 

Add-on Profile v2.00 for Studio 5000 Logix Designer software will contain fully functional Logic editor for the Guardmaster 440C-CR30 safety relay.



Single software/project for configuring and monitoring Logix controller and

Guardmaster 440C-CR30 safety relays.

Guardmaster 440C-CR30 Safety Relay Easy to Use Configure Device

Configure Safety Function

Configured in CCW and Studio5000

Logic configured with Simple Drag and Drop Function Block Editor

Validate and Verify Checklist to walk through validation and verification process

Demonstration Time DONE!

Assigned safety function via Drag ’n’ Drop Ease of configuration – No previous programming skills required 68



Safe Motion

ControlLogix L7x Features (>V20) User Memory

1756-L71

1756-L72

1756-L73

1756-L71S

1756-L72S

1756-L73S

2 MB

4 MB

8 MB

2 MB

4 MB

8 MB

1 MB

2 MB

4 MB

User Memory for safety Non-Volatile Memory Common Applications

Secure Digital Discrete machine control

1784-SD1: 1784-SD2:

Multiple axis motion control, process control

1 GB 2 GB Discrete machine control, Safety, Multiple Axis Motion

Built-in Communication Ports

USB 2.0

Communication Module Options

EtherNet/IP, ControlNet, DeviceNet, legacy and 3rd party networks

Integrated Motion Programming Languages

SERCOS, CIP Motion, analog, hydraulics Relay ladder logic, function block diagram, structured text and sequential function charts

Controller Tasks Safety Task

32 tasks, 100 programs per task -

1

Ideal for sequential to large, data intensive applications

Distributed Guard I/O Choices

GuardLogix en Compact GuardLogix

RSLogix 5000

PanelView VersaView

CIP Safety over EtherNet/IP

EtherNet/IP

GuardLogix CompactGuardLogix

CIP Safety over DeviceNet DeviceNet

Dual Channel Application Instructions  Certified application instructions DCI – Start  DCI – Stop  DCI – Stop with Test 

DCI – Stop with Test & Lock  DCI – Stop with Test & Mute  DCI – Monitor 

 Focused on three main safety “Functions” Start, Stop, Monitor  Easier to use 



Reduces testing & validation effort

 Better diagnostics 73

GuardLogix SIL3 Analog  PointGuard SIL 3 Analog Input Module       

SIL3 rated analog input module for Point I/O 4 channels Accepts ±10V and 0-20mA / 4-20mA signals 12 bit resolution Single Channel & Dual Channel Supports 2, 3, and 4 wire sensors Tacho Feature

Demonstration Time

 Certified SIL 3 Analog Input Instruction Integer instruction, DCA  Floating Point instruction, DCAF 

Safety Add-On Instructions High Integrity Add-On Instructions (HIAOI)  AOI functionality available for use within Safety Routines  Internal behavior/rules follow existing Safety Task Rules  Only safety instructions are allowed  Only safety tags can be used (referenced) 

Transportable between GuardLogix projects  SIL integrity is maintained  Uses the same procedures as standard side AOI’s



Provides users significant benefits  Helps enforce consistent behavior  Reduces the risk of users creating custom logic  Reduces test and validation effort  Test once and then simply verify signature on each reuse. 75

Safety Add-On Instructions High Integrity Add-On Instructions (HIAOI) •

SIL 3 Integrity

– TUV recognized and approved implementation – Any developed safety AOI can be certified to SIL 3 (our implementation would allow it, this does not mean that TUV would approve/accept the instruction functionality) – Safety AOI’s are part of the safety task signature. – Safety signature provides security over safety AOI’s within a project

76


Scalable Safety Solutions GuardLogix Safety ToolKits

Safe Motion

Safety Accelerator Toolkit

78


79


80





IEC 61800-5-2 Funtional Safety of Power Drive Systems Safe Motion Functions Function

Operation

Safe stop

Initiate Safe Stop Category 0, 1, or 2

Zero speed monitoring

Only allow access (unlock door) when axis is stopped.

Safe limited speed

When requested, monitor speed. If in excess of safe speed, initiate Safe Stop.

Safe maximum speed

Always monitor for safe maximum speed, even under normal operation. If in excess, initiate Safe Stop

Safe direction monitoring

When requested, monitor direction. If wrong rotation direction, initiate Safe Stop

Door monitoring and control

Unlock door to grant access when at safe speed or zero speed.

Enabling switch control

Use in conjunction with Safe Limited Speed. Allow access when at Safe Speed. If no Enable Switch, initiate Safe Stop.

Safe Max Accel monitoring

When configured, if accelerating too fast, initiate Safe Stop.

Integrated Safety on EtherNet/IP How it works

Safety Message Producer to Consumer Data A

Mode

CRC-A

Data Section

normal data Inverted data

Data B

CRC-B

Time_Stamp

CRC

Time Stamp Section

> Duality > Diagnostics > Diversity

 Capable of SIL3 / PLe for Safe Torque-off

A

B

Output A

Output B

STO

STO

EtherNet/IP CIP Safety Packet provides Duality, Diagnostics and Diversity!

86

Integrated Safety on EtherNet/IP

Integrated Safety Enhances Machine Performance and Flexibility

GuardLogix

Advantage of Integrated Safety: Safety in the controller Safety over the network Improved awareness Reduced machine wiring Reduced hardware and potential for failures One software tool for configuration GuardLogix control, PowerFlex 527 AC Drives and Kinetix 5500 Servo Drives provide

Integrated Safety

Networked Zoning Save Time and Money

• Each colored area shown have drives and their respective motors grouped together. These are called “zones” •

•

In a hard wired solution, these drives would have their safety inputs daisy chained to each other In a networked solution all zoning is done completely in the controller

• If one product in any zone goes into a safe state, all products in that zone go into a safe state as well

PowerFlex 527

Kinetix 5500

Kinetix 5500

Kinetix 5500

PowerFlex 527

Kinetix 5500

Application Example #1: GuardLogix for Safety and Motion Control

Zone 2

Zone 1 Zone 1

Zone 2

Zone 2

Zone 2

GuardLogix allows machine flexibility for Motion and Safety

Safety Zoning in Logix Designer

Zone 1

Zone 2

Zone 1

•

• •

Machine safety is configured in the safety task of Logix Designer. Safety connections made through EtherNet/IP. No additional wiring is required.

Zone 1

Zone 2

Zone 2

Programmatically change the safety zones in Logix Designer

9 1

Safety Zoning in Logix Designer Zone 1 Zone 1

• • • •

Zone 2

Machine safety is configured in the safety task of Logix Designer. Cut/paste Axis from one zone to another. Safety connection to the drive via EtherNet/IP. No additional wiring is required.

Zone 1

Zone 2

Zone 2

Programmatically change the safety zones in Logix Designer

9 2

Process Safey Process Control

SIL 0 Process

SIL 1 Fail Safe

Process Safety SIL 2 Fail Safe

SIL 2 Fault Tolerance

SIL 3 Fail Safe

SIL 3 Fault Tolerance

PlantPAx (Logix) AADvance Scalable Safety

EtherNet/IP communication: AADvance™ & PlantPAx™ Trusted TMR

O&G / Petro-Chem lead with AADvance & Trusted – Others with Logix Family

Dank voor uw aandacht Vragen ?

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Schaalbare veiligheidsoplossingen

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