NHP SAFETY REFERENCE GUIDE
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1 4 NHP SAFETY REFERENCE GUIDE CONTENTS SAFETY TECHNOLOGY Risk Reduction Options Permanent Fixed Guard 4-02 Interlocked Guard: 4-03 Limit Switches 4-08 Presence Sensing Technology 4-09 Safety Laser Scanners 4-11 Safety Mats 4-12 Emergency Pull-wire Switches Safety Foot Switches 4-13
2 NHP SAFETY REFERENCE GUIDE 4. TECHNOLOGY Safety Technology
3 Risk Reduction Options: When considering a risk reduction measure there is a large range of options available, so where do you start? Firstly the correct guard must be selected for your specific application, information can be found in the various state occupational safety ACTs and Regulations. For national reference, the following Guarding Hierarchy can be found in the National Occupational Health & Safety Commission (NOHSC) National Standard For Plant (1994). When guarding is to be used as the risk reduction measure, the following options are available: 1. Permanent Fixed Guard, when access is not required during any mode of operation (normal use, maintenance, cleaning). 2. Interlocked Guard, when access is required. 3. Fixed Guard, when the above two options are not practicable. 4. Presence Sensing System, when the above three options are not practicable. Another good reference point for guard selection is AS So let s look at the considerations for the above options: Permanent Fixed Guard: This guard is used in applications where access is never required for any operational mode, this would include normal operation, cleaning, maintenance. The guard must be attached by permanent means (by welding), so the guard would need to be destroyed to gain access to the hazardous zone. Some examples of permanent fixed guarding are shown (figures 1 and 2). Advantages: The permanent fixed guard achieves complete removal of the person from the hazardous area The permanent fixed guard is the simplest guarding option because no reliance on an electrical control system or work procedure is needed. Only maintenance issues of the guard itself need to be considered. Only should be used where access is never required. Figure 1: Cut away view of permanent fixed casing. Figure 2: Cut away view of permanent fixed casing. NHP Safety Reference Guide > NON APR > 4. Safety Technology 4-2
4 Interlocked Guard: This guard may be opened to allow access to the hazardous area, but an interlocking device must be associated with the system so that: The hazardous operation of the equipment can t occur until the guard is closed If the guard is opened during the equipment s operation, a stop command is initiated When the guard is closed it should not, by itself, initiate hazardous operation. A range of different technologies are available when it comes to deciding on an interlock device, some considerations for the various options are as follows: Tongue Interlock Switch: Tongue operated interlock switches require a tongue shaped actuator to be inserted and removed from the switch. When the tongue is inserted in the switch, this means the guard is closed, the safety contacts are closed and the machine is allowed to operate When the tongue is removed from the switch, this means the guard is open, the safety contacts are open and a stop command is initiated. One main requirement of any interlock switch is the ability to minimise defeat possibilities. One way to achieve this with a tongue interlock switch is to mount the switch in a way that it is protected from being tampered with (e.g: mounting switch under a cover or some other means that restricts access to the switch especially when the guard is open). The other way to avoid tampering is the shape of the actuator. The actuator is mechanically coded in a similar way to a key. Also, mechanisms can exist on the actuator that will eject the device from the switch. These tamper resistant requirements are set out in clause 6.7 of AS When using a tongue interlock switch it should be mounted in the positive mode according to Appendix B of AS This requires that when the guard door opens and the tongue exits the switch the safety contacts will open. Another feature of tongue interlock switches is they will use direct opening action (positive break) contacts. This requires that the contacts will be driven open by non-resilient means (not springs or gravity) when the tongue is removed. The contacts are required to fulfil the concepts of IEC to display the direct opening action symbol on the switch (refer to figure 5). As the reliability of the switch depends heavily on the tongue mechanism, these switches generally need to be used with a redundant switch. In many cases a non-electromechanical switch (e.g: coded magnetic interlock switch) can be used in conjunction with a tongue interlock, this provides diversity and reduces the chance of both switches failing due to a common cause. Figure 3: Example of installation of Tongue Interlock Switches Figure 4: Door opening horizontally Figure 5: Door opening vertically NHP Safety Reference Guide > NON APR > 4. Safety Technology 4-3
5 Interlocked Guard: Tongue Interlock Switch (cont): Advantages: Electromechanical operation means that the direct opening action principle can be used for the safety contact The mechanism of the switch provides consistent actuation with small displacement of the guard. For high integrity safety systems a redundant switch should be used because the tongue actuator can be a single point of failure Alignment issues, especially for hinged guards with small arc radius, can create mechanical wear on the actuator and lead to failure Correct switch body must be selected to match the size and inertia of the guard door. Incompatible selection can lead to mechanical failure of the switch or guard door Tongue interlock switches can be difficult to clean thoroughly, so they may not applicable for some pharmaceutical or food/beverage applications. Hinge Switches: These switches are mounted over the hinge-pin of a hinged guard. As the guard opens the shaft rotates and switches the safety contacts to the open state, this will initiate a stop command. An advantage of the hinge switch over the tongue interlock switch is the increased tamper resistance that can be achieved. In many cases the switch can only be bypassed by virtually destroying the guard. As with the tongue interlock switches, these switches are electromechanical devices, thus the same features are consistent in their application (for more information on the following principles refer to the Tongue Interlock Switch section): When one switch is used, it should be positive mode mounted The normally closed safety contacts use the principle of direct opening action The switch reliability is reliant on the mechanical integrity of the actuator, thus a redundant switch should be used for high integrity systems. Advantages: Electromechanical operation means that the direct opening action principle can be used for the safety contact Increased tamper resistance if installed correctly Not effected as much as a tongue interlock switch due to misalignment when used with a small arc radius hinged guard. Figure 6: Example of installation of Hinge Switch NHP Safety Reference Guide > NON APR > 4. Safety Technology 4-4
6 Interlocked Guard: Hinge Switches (cont): For high integrity safety systems a redundant switch should be used because the tongue actuator can be a single point of failure Alignment issues can create mechanical wear on the actuator and lead to failure Correct switch body must be selected to match the size and inertia of the guard door.incompatible selection can lead to mechanical failure of the switch If arc radius of the guard door is very long, the opening movement of the hinge switch (typically 3º) may result in a significant gap at the opening edge. On sliding guards Guard Locking Switches (Solenoid Interlocks): In some applications it is required that access to the hazardous area is restricted, this may be because of the following reasons: On hinged guards a) The machinery may have a long response time to a stop command, this may be due to high inertia, thus access is only granted once the machinery has reached a safe state b) It may be advantageous to control the access to the equipment, for example stopping a machine mid-cycle may result in loss of material or information so access is only granted once the equipment has reached a certain state. A common device that can be used for controlling access to the hazardous area is a solenoid interlock switch. This device works with the same principle as a tongue interlock switch but the actuator will be mechanically locked inside the switch until the unlock signal is sent to the solenoid inside the device which then releases the actuator. On removable guards Figure 7: Example of installation of Solenoid Interlock switch NHP Safety Reference Guide > NON APR > 4. Safety Technology 4-5
7 Interlocked Guard: Guard Locking Switches (Solenoid Interlocks) cont: The locking mechanism can operate in the following ways: Figure 8: Operating modes of a Solenoid locking device, sourced from AS NHP Safety Reference Guide > NON APR > 4. Safety Technology 4-6
8 Interlocked Guard: Guard Locking Switches (Solenoid Interlocks) cont: The power-to-release mode is usually required in safety applications, according to AS clause 6.5. This mode will require power to be supplied to the solenoid in the switch to unlock the actuator and allow access to the hazardous area. The system that sends the unlock signal to the solenoid can operate in three common configurations: 1. The action of sending a stop signal to the machinery initiates a safe timer, that will send the unlock signal to the solenoid after a set delay time. a. This is the simplest form of safely controlling access to the hazardous area. b. The time delay should be greater then the worst case stopping time and the stopping time should be predictable and consistent. 2. The speed of the machinery is monitored by sensors (e.g: proximity sensors or encoder). Once the sensors detect that the machine has reached standstill, the unlock signal is sent to the solenoid. 3. The motor of the machine produces back emf voltage when it is free-wheeling, once the emf of the motor has ceased being generated this indicates that the hazardous motion has stopped. When the back emf is no longer generated then the unlock signal is sent. As with the tongue interlock switches these switches are electromechanical devices, thus the same features are consistent in their application (for more information on the following principles refer to the Tongue Interlock Switch section): When one switch is used, it should be positive mode mounted The normally closed safety contacts use the principles of direct opening action The switch reliability is reliant on the mechanical integrity of the actuator thus a redundant switch should be used for high integrity systems. Advantages: Electromechanical operation means that the direct opening action principle can be used for the safety contact The mechanism of the switch provides consistent actuation with small displacement of the guard The ability to lock the actuator inside the switch allows the safety system to allow access when safe or when convenient. For high integrity safety systems a redundant switch should be used because the tongue actuator can be a single point of failure Alignment issues, especially for a hinged guards with small arc radius, can create mechanical wear on the actuator and lead to failure Correct switch body must be selected to match the size and inertia of the guard door. Incompatible selection can lead to mechanical failure of the switch or guard door Tongue interlock switches can be difficult to clean thoroughly, so they may not be applicable for some pharmaceutical or food/beverage applications. NHP Safety Reference Guide > NON APR > 4. Safety Technology 4-7
9 Interlocked Guard: Non-Contact Interlock Switches: Non-contact switches operate by the sensing unit detecting the actuator when it is in close proximity, the technology used for this detection can be: Coded magnetic RFID One feature of the non-contact switches is their ability to minimise tampering. For the non-contact switch this can be achieved by using the following techniques: Coding, the sensing mechanism should be coded so it can t be defeated easily. For example if using a magnetic reed switch the actuator should be a coded magnet so a common magnet can t be used to bypass the system Mounting, the mounting of the switch should minimise access. On sliding guards When using a non-contact switch it is important to understand the contacts are not direct opening action. Because of this the contacts must be protected from over current that may lead to welding. This means the non-contact switch should always be interfaced to a device that will limit current. This is why non-contact switches should always be monitored by a matching safety relay. Advantages: Better tolerance for misalignment then tongue interlock switches No single point of mechanical failure, so if mounted correctly can be used without redundant switches to achieve high levels of safety integrity Much easier to clean then many mechanical devices, therefore can be used in the food/beverage industry. Contacts are not direct opening action, thus must always be interfaced to a device that protects the contacts from over current. Limit Switches: a: Actuating angle from right of switch axis. b: Actuating angle from left of switch axis. Actuating angle from bottom of switch axis. Figure 9: Example of safety limit switches. Limit switches can be used to detect the opening of a guard, when using one limit switch it must be mounted in the positive mode orientation. As with all mechanical devices they should be mounted with a redundant device for high integrity safety systems. When using two limit switches on a guard door they should be mounted in the following combination: One switch should be mounted in positive mode One switch should be mounted in non-positive mode. This requirement will give the system tolerance to common cause failures and is a requirement of clause 7 AS NHP Safety Reference Guide > NON APR > 4. Safety Technology 4-8
10 Presence Sensing Technology: Presence sensing technology is a range of products that do not restrict access to the hazardous area but they detect the presence of a person in the hazardous area. A main consideration is the safety distance of the presence sensing device from the hazard itself. The general requirements for the calculation of safety distances according to the Australian Standards are contained in: AS Safeguarding of Machinery Installation and commissioning requirements Optoelectronic requirements. Where: S = (K x T) + C S Minimum safety distance (mm) S shall not be less then 100 mm. For non-industrial environments add 75 mm to the calculated value of S. If light curtains are used for reinitiation of machine operation, the light curtain resolution is equal or less than 30 mm and the value of S must be greater than 150 mm. K T C Approach speed of object to the hazard (mm/sec) Overall system stopping performance (sec) T = t1 + t2 Additional distance (safety factor) C = 8(d 14) d = resolution of the light curtain Initially use the default value of K (2000 mm/s) in the equation, if the value of S is calculated to be greater than 500 mm then recalculate the equation using a value of 1600 mm/s for K. When light curtains are used in an application where the user is making rapid repetitive motions and is contained to a small workplace the value of K shall be 2500 mm/s. For non-industrial applications the value of K will be 2000 mm/s t1 maximum time between actuation of sensing function and the output signal switching devices being in the OFF state (sec) t2 maximum response time of the machine (sec) If the resolution of the light curtain is mm then C = 850 mm Example: Calculate the safety distance required when using a 14 mm resolution light curtain to guard a point-of-operation hazard for which the response time between the light curtain actuation and safety controller switching is 18 ms and the machine stop time is 60 ms and the safety factor is negligible. S = 2000 mm/sec x ( ) S = 156 mm Table 1: Safety distance calculation. NHP Safety Reference Guide > NON APR > 4. Safety Technology 4-9
11 Presence Sensing Technology: Some of the common presence sensing devices are as follows: Safety Light Curtains: The light curtain system consists of an emitter and a receiver that create a barrier of infrared light. As with the other safety devices light curtains are designed to be tamper resistant, the beams are pulsed and the receiver is synchronised to the emitter, this eliminates the effect of interference from other sources of infrared light. Light curtains can have their own diagnostics built inside so faults such as channel to channel shorts can be detected, feedback from switching devices such as contactors can also be wired directly to the light curtain. Features such as the previous two allow the light curtains to be configured in a two box system which means no safety relay is required. Light curtains can also be set up to function in many different ways, which allows them to be able to adapt to many applications where other types of guard do not offer the flexibility or functionality required. Figure 10: Example of safety light curtains Cascading: This is the process of connecting one set of light curtains to another, in this situation one set of light curtains is the host and the other light curtain acts as the guest, two guest sets can be cascaded to one host. The benefit of cascaded light curtains is the reduction in wiring and input terminals to logic devices. However the response time of the system is increased, this must be considered when calculating the safety distance. Fixed and Floating Blanking: Blanking allows portions of the light curtain field to be disabled to allow objects that are associated with the process to be ignored while the light curtain remains activated. Fixed blanking can be used for static objects which do not move, where an object such as a conveyor or machine section exist in the blanked section of the light curtain. Floating blanking allows the user to configure a blanking window, which can be two beams wide for a 14 mm resolution light curtain and one beam for a 30 mm resolution light curtain. This window can exist anywhere in the light curtain except the synchronisation beam, this allows for objects to move in the light curtain field as long as they don t break more the maximum allowable beams. NHP Safety Reference Guide > NON APR > 4. Safety Technology 4-10
12 Presence Sensing Technology: Muting: Muting allows the light curtain operation to be suspended to allow objects, such as pallets of goods, to enter and leave the hazardous area. Sensors, commonly photoelectric sensors, are used to detect the muting situation and initiate the suspension of the light curtain. Advantages of Light Curtains: Good option for very high frequency access applications Allows for functionality that mechanical guards can t accomplish, such as muting, floating blanking. Can be used without a safety relay. Light curtains do not offer a physical barrier, thus: They can t be used to control access to the hazardous area They can t protect against projectiles, noises, emissions They may effect the risk assessment because frequency of access may increase due to accidental entering of the hazardous area by inexperienced people. Light curtains can t be used for machines with high inertia and stopping times because the safety distance would quickly become unworkable and present a high risk of someone being undetected in the hazardous area while operation is initiated Light curtains should be used in an application where there is no excess dust or dirt. Figure 11: Example of Light curtains arranged in a muting application. Safety Laser Scanners: Laser scanners operate by creating a field of laser beams and detect objects that enter this field. The scanner can be configured to have a safety zone of a particular shape and size, it can also be configured to have a warning zone. Multiple safety zones can also be created so only applicable equipment is switched off when a person enters a safety zone. Advantages of Laser Scanners: Laser scanners can be used without a safety relay More flexibility then light curtains or safety mats because the field can be configured. Figure 12: Example of safety light curtains NHP Safety Reference Guide > NON APR > 4. Safety Technology 4-11
13 Safety Laser Scanners cont: Laser scanners do not offer a physical barrier, thus: They can t be used to control access to the hazardous area They can t protect against projectiles, noises, emissions They may effect the risk assessment because frequency of access may increase due to accidental entering of the hazardous area by inexperienced people. Laser scanners can t be used for machines with high inertia and stopping times because the safety field is usually limited, e.g: 5 m, so the stopping time of the equipment must be reasonably fast Objects such as poles or other structures inside the safety field can cause shadows in the Laser scanner s field. Safety Mats: Safety mats can be mounted on the floor of the hazardous area to detect a person, generally used as a secondary device to avoid start-up of the equipment when a person is present in the hazardous zone. Advantages of Safety Mats: Can be a simple solution Is able to detect in hazardous areas that would be difficult for light curtains or scanners to detect Can be custom built around objects such as poles, which cause shadows in laser scanner fields. Generally need to be mounted on flat surfaces If the mat profile degrades and allows water to enter the mat, dead zones can be created inside the mat. NHP Safety Reference Guide > NON APR > 4. Safety Technology 4-12
14 Emergency Pull-wire Switches: Emergency pull-wire switches are of great importance for the man-machine interface in the area of industrial applications. They are, for example, applied on transport and conveyor systems. After manual actuation, work and functional processes are initiated or switched off. On emergency pull-wire switches the emergency-stop command can be initiated from any point along the pull-wire. They have a positive linkage between the NC contacts and the pullwire. The emergency pull-wire switches are brought into the operational condition by pretensioning the pull-wire, i.e. the NC contacts are then closed and the NO contacts are open. All devices are equipped with wire-breakage detection. In the chapter accessories of the appendix the required accessories for installation are presented. There are devices with one- and two-side actuation. The wire length, the number of contacts and the mounting position, in the middle or on one side of the system, are the main features when selecting an emergency pull-wire switch. Safety Foot Switches: Figure 13: Example of Emergency Pull Wire switch Safety foot switches are mounted on machines and plants as enabling switches in cases where operation using the hands is not possible. When the foot pedal is actuated to as far as the pressure point, the NO contact is closed. If, in case of danger, the pedal is actuated beyond the pressure point, then the positive break NC contact is opened and mechanically latched. Reset operation is carried out by means of a push button. The function principle of all safety foot switches is also shown in the drawing below. Figure 14: Example of Safety Foot switch NHP Safety Reference Guide > NON APR > 4. Safety Technology 4-13
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