Machinery Safety
Presented by Paul Laidler
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24/09/2013
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Slide 1
Machinery Division
Assistance in meeting the requirements of machinery safety legislation
Machinery, Low Voltage and Electro Magnetic Compatibility (EMC)
Directives
Work Equipment Directive PUWER and LOLER
Comprehensive risk assessments
Guidance on technical file construction and declaration of
conformity/incorporation
Pre-purchasing CE Audits
Safety Related Control System validation
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Slide 2
Formal Training
3 University Certificate Courses in Professional Development:
European Machine Safety Requirements
Electrical Machinery Safety
Functional Safety
Accredited by the University of Teesside
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Slide 3
Machinery Safety Engineering Services
Engineering design
Site survey and function design specification
Factory acceptance test
Installation and commissioning
Machine guarding
Design, manufacture and installation of machine guarding and Safety
Related Control Systems
Solutions include perimeter guarding, light curtains, scanners, interlocking
etc.
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Slide 4
Risk assessment
1.
Determine the limits of the machine
2.
Hazard identification
3.
Risk estimation
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Slide 5
Determine the limits of the machine
Use limits
Space limits
Time limits
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Slide 6
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Slide 7
Limits of machine Use limits
Use limits
Personnel operating the machine
how competent/what age?
any impairments
visual/hearing/physical?
male/female?
Other personnel in the vicinity
other operators
non-operator employees
non-employees
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Slide 8
Limits of machine Space limits
Space limits
Physical limits of the machine to
be assessed
Range of movement
Space requirements for
operation and maintenance
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Limits of machine Time limits
Time limits
Life limit general wear and tear
Maintenance intervals
Housekeeping
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Slide 10
Hazard identification
Mechanical
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Slide 11
Hierarchy Of Control
Control Measures
Design the hazard out.
Remove the need for man machine interface.
Design in safeguards.
Reduce the possibility of occurrence.
Reduce the degree of harm.
Warn and inform (but only if you can achieve adequate safety).
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Slide 12
Risk reduction
INITIAL
DESIGN
DESIGN
OUT
HAZARDS
RISK
REDUCTION
RISK
REDUCTION
SAFETY
CONTROLS
INFORMATION TRAINING
ORGANISATION
SAFE SYSTEMS
OF WORK
RISK
REDUCTION
RISK
HIGH
PROTECTIVE
MEASURES
RISK
REDUCTION
RISK
REDUCTION
LOW
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Slide 13
Risk reduction
INITIAL
DESIGN
PROTECTIVE
MEASURES
RISK
REDUCTION
SAFETY
CONTROLS
INFORMATION TRAINING
ORGANISATION
SAFE SYSTEMS
OF WORK
RISK
REDUCTION
RISK
HIGH
DESIGN
OUT
HAZARDS
RISK
REDUCTION
RISK
REDUCTION
RISK
REDUCTION
LOW
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Slide 14
Design out the hazards
Mechanical risk
reduction involves
removing or reducing
to a minimum trap, nip
or pinch points.
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Slide 15
Risk reduction
INITIAL
DESIGN
PROTECTIVE
MEASURES
RISK
REDUCTION
SAFETY
CONTROLS
INFORMATION TRAINING
ORGANISATION
SAFE SYSTEMS
OF WORK
RISK
REDUCTION
RISK
HIGH
DESIGN
OUT
HAZARDS
RISK
REDUCTION
RISK
REDUCTION
RISK
REDUCTION
LOW
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Slide 16
Protective measures (Guarding)
To prevent access
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Protective measures (Guarding)
To reduce risks from debris and ejected parts
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Slide 18
Protective measures (Guarding)
To reduce risks of damage from outside (e.g. FLTs)
Barriers
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Slide 19
Risk reduction
INITIAL
DESIGN
PROTECTIVE
MEASURES
RISK
REDUCTION
SAFETY
CONTROL
S
INFORMATION TRAINING
ORGANISATION
SAFE SYSTEMS
OF WORK
RISK
REDUCTION
RISK
HIGH
DESIGN
OUT
HAZARDS
RISK
REDUCTION
RISK
REDUCTION
RISK
REDUCTION
LOW
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Slide 20
Safety circuits guards
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Slide 21
Safety circuits guards
Allows the gate
lock to be
unlocked
De-energise
the machine
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Slide 22
Safety circuits guards
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Slide 23
Safety circuits guards
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Slide 24
Risk reduction
INITIAL
DESIGN
PROTECTIVE
MEASURES
RISK
REDUCTION
SAFETY
CONTROLS
INFORMATION
TRAINING
ORGANISATION
SAFE SYSTEMS
OF WORK
RISK
REDUCTION
RISK
REDUCTION
RISK
HIGH
DESIGN
OUT
HAZARDS
RISK
REDUCTION
RISK
REDUCTION
LOW
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Slide 25
Information
Information may take the form of:
manuals for operation, maintenance
and safety;
drawings and parts lists;
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Slide 26
Information
Notices, can be of several forms
such as warning, mandatory and
prohibition
Service information
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Slide 27
Risk reduction
INITIAL
DESIGN
PROTECTIV
E
MEASURES
RISK
REDUCTION
SAFETY
CONTROL
S
RISK
REDUCTION
INFORMATION
TRAINING
ORGANISATION
SAFE SYSTEMS
OF WORK
RISK
REDUCTION
RISK
HIGH
DESIGN
OUT
HAZARDS
RISK
REDUCTION
RISK
REDUCTION
LOW
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Slide 28
Training, Organisation and SOP
Organisation includes:
a coherent Health and Safety structure,
a management structure with clearly defined responsibilities,
an involved workforce,
safe systems of work.
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Slide 29
Legislation
Machinery Directive
2006/42/EC
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Slide 30
HSE Horse
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Slide 31
Machinery Directive EHSRs
1.3.7 Risks related to moving parts
The moving parts of machinery must be designed and constructed in such a
way as to prevent risks of contact which could lead to accidents or must be
fitted with guards or protective devices.
1.3.8 Choice of protection against risks arising from moving parts
Guards or protective devices designed to protect against risks arising from
moving parts must be selected on the basis of the type of risk.
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Slide 32
Machinery Directive EHSRs
1.4.1 General requirements
Guards and protective devices must:
be of robust construction,
be securely held in place,
not give rise to any additional hazard,
not be easy to by-pass or render non-operational,
be located at an adequate distance from the danger zone,
cause minimum obstruction to the view of the production process,
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Slide 33
Machinery Directive EHSRs
1.4.1 General requirements cont
In addition, guards must, where possible, protect against the ejection or
falling of materials or objects and against emissions generated by the
machinery.
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Slide 34
Machinery Directive EHSRs
[Link] Fixed guards
Fixed guards must be fixed by systems that can be opened or removed only
with tools.
Their fixing systems must remain attached to the guards or to the machinery
when the guards are removed.
Where possible, guards must be incapable of remaining in place without
their fixings.
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Slide 35
Machinery Directive EHSRs
[Link] Interlocking movable guards
Interlocking movable guards must be designed in such a way that the
absence or failure of one of their components prevents starting or stops the
hazardous machinery functions.
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Slide 36
Protective measures (Guarding)
To prevent access
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Slide 37
Machinery Directive EHSRs
1.6.4 Operator intervention
Machinery must be so designed, constructed and equipped that the need for
operator intervention is limited. If operator intervention cannot be avoided, it
must be possible to carry it out easily and safely.
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Slide 38
Legislation
Machinery Directive
2006/42/EC
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Slide 39
Definition of a Safety Component
Which serves to fulfil a safety function,
which is independently placed on the market,
the failure and/or malfunction of which endangers
the safety of persons.
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Slide 40
Definition of a Safety Component
Safety devices that fall under the scope of the Directive Annex V
Indicative list:
Extraction systems.
Guards and protection devices.
Control devices for calling lifting appliances and anti fall devices for hoists.
Protective devices designed to detect the presence of a person.
Safety belts and seat harnesses.
Hydraulic non return valves where they are used to prevent falls.
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Slide 41
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Slide 42
Legislation
Provision and Use of Work
Equipment Regulations 1998
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Slide 43
PUWER 98 Regulations
Regulation 5 Maintenance
(1) Every employer shall ensure that work equipment is maintained in an
efficient state, in efficient working order and in good repair.
(2) Every employer shall ensure that where any machinery has a maintenance
log, the log is kept up to date.
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Slide 44
PUWER 98 Regulations
Regulation 11 Dangerous parts of machinery
(1) Every employer shall ensure that measures are taken
(a) to prevent access to any dangerous part of machinery or to any rotating part
or
(b) to stop the movement of any dangerous part of machinery or rotating part
before any part of a person enters a danger zone.
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Slide 45
Dangerous parts of machinery
Q Is there access to dangerous parts of machinery?
Q Are all guards securely held in place?
Q Can the guarding be bypassed or disabled?
Q Are interlocks fitted, positive acting, correctly positioned and
functional?
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Slide 46
R11 Dangerous parts of machinery
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Slide 47
R11 Dangerous parts of machinery
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Slide 48
R11 Dangerous parts of machinery
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Slide 49
Use of Standards
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Slide 50
The Role of EN Standards
Machinery manufactured in conformity with specified published European
Harmonised standards will be presumed to comply with the Essential Health
and Safety Requirements covered by those standards
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Slide 51
The Role of EN Standards Globally
Many of the Standards now utilised in Europe are now globally recognised
standards
ISO
IEC
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Slide 52
Types of EN Standard
A type apply to all machines
B type are designed to promote safety and split into B1 and B2
C type apply to a specific type of machine
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Slide 53
Types of EN Standard
IEC 60204 - 1
Electrical
Equipment
BS EN 12100- 2010
Safety of machinery,
general principles for
design and risk
assessment.
BS EN ISO 13857
Upper and Lower limb
access.
TYPE C
STANDARDS
for Machines
BS
ISO
13850
PR
EN
418
Emergency Stop
Emergency
Stop
BS EN 414
Safety of machinery
Rules for drafting and
Presentation of safety
standards
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DEVICE STANDARDS
2 Hand Controls
Light Curtains
Safety Switches etc
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Slide 54
Types of EN Standard
Type A Standards
Applies to all machinery and are essential reading for machinery builders
and modifiers
BS EN ISO 12100:2010 Safety of Machinery General principles for design
Risk assessment and risk reduction (ISO 12100:2010)
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Slide 55
Types of EN Standard
'B1' Standards
Apply to all machinery and are designed to promote the essential factors
mentioned in the foreword.
'B2' Standards
These are "apply when used" Standards, i.e. if a particular safety device is
chosen for a machine, then it must, be manufactured to the relevant
standard. E. g. Interlock switch, E stop switch.
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Slide 56
Types of EN Standard
Type C Standards
BS EN 415 Series Safety of Packaging Machines
BS EN 10218 Industrial Robots Recommendations for Safety. Parts 1 & 2.
BS EN 12417 Safety of Machine tools Machining Centres.
BS EN 692 Mechanical Presses
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Slide 57
BS EN ISO 13857
Scope
This International Standard establishes values for safety distances in both
industrial and non-industrial environments to prevent machinery hazard
zones being reached. The safety distances are appropriate for protective
structures. It also gives information about distances to impede free access
by the lower limbs.
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Slide 58
BS EN ISO 13857
Use of Tables
Reaching over protective structures:
Table 1 shall be used where there is a Low Risk
Table 2 shall be used where there is a High Risk.
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Slide 59
BS EN ISO 13857
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Slide 60
BS EN ISO 13857
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BS EN ISO 13857
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BS EN ISO 13857
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BS EN 349
This standard enables users to avoid hazards from crushing
zones. It specifies minimum gaps relative to parts the
human body.
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BS EN 349
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BS EN 953
SCOPE
This standard specifies general requirements for the design and construction
of guards provided to protect persons from mechanical hazards.
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BS EN 953
Risk assessment
In order to select and design types of guards appropriate to particular
machinery, it is important to assess the risk arising from the various hazards
present at that machinery and the foreseeable categories of persons at risk !
see EN ISO 12100
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Slide 67
Enclosing Fixed Guard
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BS EN 953
Guards are used for numerous reasons including.
Containment of ejected parts
Containment of hazardous substances
Noise reduction
Radiation containment
Explosion (blast panels designed to dissipate force)
Viewing of process
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Slide 69
Distance Guarding - Fixed
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Slide 70
BS EN 953
Guards must be suitable for purpose.
Guards shall be designed so far as is practicable to take into account
foreseeable use and reasonably foreseeable misuse.
Guards shall be designed so as not to cause hazardous crushing or trapping
points, with parts of the machine or of other guards.
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Slide 71
Combination of Guards & Protective Devices
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Slide 72
Distance Tunnel Guard
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Slide 73
BS EN 953 Selection of guards
Guards should be selected from the following in the order of priority given:
a) Local guards enclosing individual danger zones if the number of danger
zones to protect is low. This can provide an acceptable residual risk and
permits access to non-hazardous machine parts for maintenance, setting,
etc.
b) A guard enclosing all the danger zones if the number or size of the danger
zones is high. In this case setting and maintenance points should, as far as
possible be located outside the guarded area.
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Slide 74
Suitability of guards
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Safety Related Control System
A protection device or interlocking system should be designed so that it will only
operate as intended.
Furthermore, if a component deteriorates or fails, the device or system should
as far as possible fail in a safe manner by inhibiting the dangerous action of the
machine.
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Slide 76
EN 13849
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END
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Slide 78
