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Introduction to
Functional Safety
3. Key Technologies
4. Summary
Functional
Safety
Falling Radiation
Electric Shock
Temperature
Noise
Crushing Chemicals
Safety
• Physical • Electrical
– Falling / Moving Objects – Flashover and Burns
– Collisions
– Electrocution
– Collapsing Structures
– Wrong Connection / Loose Connection
Layers of Protection
Risk
+ =
+ =
Most
Design it out Preferred
Monitoring
Personal protective
Least
equipment Preferred
Safety
System
• Each hazard on a machine will consist of one or more “safety loops” that monitor and
control its supply of energy
– As determined by the risk assessment
• Each safety product must be applied as part of a whole to effectively reduce risk
– Safety is the sum of its parts and safety is only as good as its weakest link
• The complexity of the inputs (sensors) and outputs (actuators) and the flexibility of the
control will determine the type of logic solver
– Stand-alone relay, modular relay or safety PLC
1. What is Safety
2. Modern Safety Systems
3. Key Technologies
4. Summary
• Is Safety New? - NO
• Is Safety Important? - YES
• Who is Responsible? - EVERYONE
• Are Safety and Productivity initiatives ever at odds?
• Are Safety Systems or Procedures Ever Bypassed?
• Are people ever injured in manufacturing machinery
accidents?
• Goals: Integrated Controls Solutions that are
safer AND more productive BY DESIGN.
• Reactive or Proactive?
• Safety philosophy driven from top
down
– Safety credo, specifications, etc.
• Safety driven from the bottom up
– Safety addressed on a case-by-case basis
(injury by injury!)
• Are formal Risk Assessments being
performed?
• Is safety Designed In or Added On?
What is Your Company Culture?
• Safety Impacts:
– Floor space/Footprint via performance (Safe Distance)
• Big money!!
– Direct Labor Content and Operator Efficiencies
• HUGE money!!
– Ergonomics
– Productivity (System Design considerations)
– Insurance Costs, Cost of Doing Business
– Employee Morale, Company Goodwill, Labor Relations
MTTR = 12 minutes
Machine Stops
Maintenance Arrives
Fault Identified
Repair Performed
LOTO
Production Resumes
Repair Tested
1. What is Safety
2. Modern Safety Systems
3. Key Technologies
4. Summary
• Important Concept
“What makes a product safe is that it is designed using safety principles
and complies with recognized safety standards”
• What are the principles common in products designed for safety?
– The Three D’s of Safety – Duality, Diversity, Diagnostics
– All safety products are designed using a combination of the Three D’s
– The Three D’s are used so the system will react properly when a fault occurs (e.g.
turn off outputs)
• Diversity
– Protects against two things failing in exactly the same way at the same time
– Example: Using one NO and one NC set of contacts
– Example: Using both a high and a low input channel to a safety device
• Diagnostics
– Safety products spend much of their time performing self-diagnostics
D
– If a problem is detected, the system will go to its “safe state”
D
and will not allow the system to be restarted until the problem is fixed
D
– Example: A safety PLC has a significantly higher degree of
self-diagnostic versus a standard PLC (> 90% vs. ≈ 50%)
Standard PLC
Input Module
Output Module
Safety PLC
Duality
Input Module
Diagnostics
Output Module
Diversity
Can you find the Three D’s???
Copyright © 2006 Rockwell Automation, Inc. All rights reserved. 36
Structure of a Safety Relay System
Diagnostics
Diversity
Duality
– Actuating force drives contacts open (breaks welds). when actuator is removed
– These are the type of contacts that are in Safety Interlock Switches.
Symbol
– Does not rely on a spring to open contacts such as a Limit switch. Found on
• Mechanically Linked Switch
– Linked means that if one contact welds, all contacts stay closed – for
monitoring!
– These types of contacts are found in Safety Contactors and relays to
detect faults.
• Redundant Contacts
Symbol
– Redundant contacts act as a back-up to each other in case a contact Found on
were to fail. This provides a higher degree of reliability Front of
– Example: Two normally closed, (1) N.O. and (1) N.C., or (2) PNP outputs Contactor
• Tamper Resistance
– Features designed into safety components inherently make the device
more safe.
– EXAMPLE: Coded magnetic safety switches
• All safety rated products are developed to meet specific standards for safety
– EN 954-1 (Safety Categories)
– IEC 61508 (Safety Integrity Levels for Programmable Safety Systems)
– EN 1088 (Safety Interlocks)
• Most safety rated products are certified by professional 3rd party organizations to
demonstrate compliance to specific safety standards
– Examples of third party certification organizations include TUV Rheinland, TUV Nord and BG
www.tuv.com
Copyright © 2006 Rockwell Automation, Inc. All rights reserved. 40
Questions so far...
1. What is Safety
2. Modern Safety Systems
3. Key Technologies
4. Summary
1. What is Safety
3. Key Technologies
4. Summary