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TÜV SÜD Product Service

Machinery Safety

Presented by Paul Laidler


Machinery Division Safety Solutions

• 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


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.


HSE Horse


• Machinery Directive

2006/42/EC

Legislation


• 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, where

risks persist, 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.

Machinery Directive EHSR’s


• 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,



• 1.4.1 General requirements cont

• Guards and protective devices must:

− enable essential work to be carried out on the

installation and/or replacement of tools and for

maintenance purposes by restricting access

exclusively to the area where the work has to be

done, if possible without the guard having to be

removed or the protective device having to be

disabled.

• In addition, guards must, where possible, protect

against the ejection or falling of materials or objects

and against emissions generated by the machinery.



• 1.4.2.1 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.



• 1.4.2.2 Interlocking movable guards must

− as far as possible remain attached to the machinery

when open,

− be designed and constructed in such a way that they

can be adjusted only by means of an intentional

action.

• Interlocking movable guards must be associated

with an interlocking device that:

− prevents the start of hazardous machinery functions

until they are closed and

− gives a stop command whenever they are no longer

closed.



• 1.4.2.2 Interlocking movable guards (cont) must

• 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.



• 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.



Definition of a Safety Components • 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.

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.

Definition of a Safety Component


• Provision and Use of

Work Equipment

Regulations 1998

Legislation


• 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.

PUWER 98 Regulations


• Regulation 11 Dangerous parts of machinery

(1) Every employer shall ensure that measures are

taken in accordance with paragraph (2) which are

effective –

(a) to prevent access to any dangerous part of

machinery or to any rotating stock-bar; or

(b) to stop the movement of any dangerous part of

machinery or rotating stock-bar before any part of a

person enters a danger zone.




(2) The measures required by paragraph (1) shall

consist of –

• (a) the provision of fixed guards enclosing every

dangerous part or rotating stock-bar where and to the

extent that it is practicable to do so, but where or to

the extent that it is not, then

(b) the provision of other guards or protection devices

where and to the extent that it is practicable to do so,

but where or to the extent that it is not, then




(b) be of good construction, sound material and

adequate strength;

(c) be maintained in an efficient state, in efficient

working order and in good repair;

(d) not give rise to any increased risk to health or

safety;

(e) not be easily bypassed or disabled;

(f) be situated at sufficient distance from the danger

zone;



• Explanation of safeguarding terms, regulation 11(2)

• GUARDS are physical barriers which prevent access

to the danger zone.

• FIXED GUARDS in regulation 11(2)(b) have no

moving parts and are fastened in a constant position

relative to the danger zone (see Figure 1).

• They are kept in place either

permanently, by welding for

example, or by means of

fasteners (screws, nuts etc)

making removal/opening

impossible without using tools.

PUWER 98 Regulations – Appendix II


• Explanation of safeguarding terms, regulation 11(2)

• If by themselves, or in conjunction with the structure

of the equipment, they ENCLOSE the dangerous

parts, fixed guards meet the requirements of the first

level of the hierarchy.

• Note that fixed enclosing guards, and other types of

guard, can have openings provided that they comply

with appropriate safe reach distances (see BS EN

13857).



• OTHER GUARDS in regulation 11(2)(b) include

movable guards which can be opened without the

use of tools, and fixed guards that are not fully

enclosing.

• These allow limited access through openings, gates

etc for feeding materials, making adjustments,

cleaning etc (see Figure 2).

• MOVABLE GUARDS may be power-operated, self-

closing, adjustable etc and are likely to require an

interlocking device so that:



(a) the hazardous machine functions covered by the

guard cannot operate until the guard is closed;

(b) if the guard is opened while hazardous machine

functions are operating, a stop instruction is given;

(c) when the guard is closed,

the hazardous machine

functions covered by the

guard can operate, but the

closure of the guard does

not by itself initiate their

operation.



• Adequate INFORMATION, INSTRUCTION, TRAINING

AND SUPERVISION are always important, even if the

hazard is protected by hardware measures, however,

they are especially important when the risk cannot be

adequately eliminated by the hardware measures in

regulation 11(2)(a) to (c).

• It may be necessary to lay down procedures to define

what information, instruction, training and supervision

must be given, and to restrict use of the equipment to

those who have received such instructions etc.




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).

.

Hierarchy Of Control


Use of Standards


• Can be used to demonstrate conformance with

regulations.

• Approved Codes of Practice refer to EN standards

• CE Marking Guidance refers to EN Standards

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

The Role of EN Standards


Now that’s what I call a hedge trimmer!


• Risk assessment must be carried out to

– Determine the limits of the Machinery

– Identify Hazards

– Estimate Risk and Evaluate

– Adequate Risk Reduction

• Design out hazard

• Reduce risk, lower power, speed etc

• Guard or protect

• Information and Warnings

• Re-assess and evaluate until acceptable

Risk Assessment (BS EN 12100:2010)


• Risk Reduction must consider

– Stability

– Maintainability

– Ergonomic Principles

– Electrical Hazards – BS EN 60204-1

– Hydraulic Hazards – BS EN 4413

– Pneumatic Hazards – BS EN 4414

– Safety related control systems – BS EN 13849/62061

– Electro Magnetic Compatibility (unexpected start)

Risk Assessment (BS EN 12100:2010)


• Mechanical risk reduction involves removing or reducing to a minimum trap, nip or pinch points.

Risk Assessment


• To reduce risks from

debris and ejected parts

Risk Assessment


• 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.

Safety Related Control System


EN 13849


• “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

Types of EN Standard


TYPE C

STANDARDS

for Machines

BS EN 12100- 2010

Safety of machinery, general principles for

design and risk assessment.

BS EN ISO 13857

Upper and Lower limb access.

PR EN 418

Emergency Stop

SPECIFIC PROTECTIVE

DEVICE STANDARDS

2 Hand Controls

Light Curtains

Safety Switches etc

IEC 60204 - 1

Electrical

Equipment

BS EN 414

Safety of machinery

Rules for drafting and

Presentation of safety

standards

BS ISO 13850

Emergency Stop



Type A Standards

• Applies to all machinery and are essential reading

for machinery builders and modifiers

• BS EN 12100:2010 Safety of Machinery – General

principles for design – Risk assessment and risk

reduction (ISO 12100:2010)



'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.



Type B Standards

• BS EN ISO 13850 Emergency stops

• BS EN ISO 13855 Relates to the positioning of

Electro-sensitive protection devices. (light curtains,

pressure mats etc).

• BS EN 953 Safety of Machinery - Guards

• BS EN 1088 Interlocking devices associated with

guards

• BS EN 4413 Hydraulic systems.

• BS EN 4414 Pneumatic systems.

• BS EN ISO 13732-1 Hot surfaces



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



• 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.

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.

BS EN ISO 13857


BS EN ISO 13857


BS EN ISO 13857


BS EN ISO 13857


BS EN ISO 13857


• This standard enables users to avoid hazards

from crushing zones. It specifies minimum gaps

relative to parts the human body.

BS EN 349


BS EN 349


SCOPE

• This standard specifies general requirements for the

design and construction of guards provided to

protect persons from mechanical hazards.

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

BS EN 953


• To minimise access to danger zones where

practicable, guards and machinery shall be so

designed as to enable routine adjustments,

lubrication and maintenance to be carried out

without opening or removing the guards.

• Where access is required within the guarded area

this shall be as free and unobstructed as practicable.

• Loading, unloading, setting, maintenance, jam

clearance, lubrication etc.

BS EN 953


Enclosing Fixed Guard


• 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

BS EN 953


Distance Guarding - Fixed


• Guards must be suitable for purpose.

• Must be able to handle guards safely, not too heavy,

unstable, have handles if hard to lift.

• Movable guards or removable sections of guards

shall be designed to permit ease of operation.

• 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.

BS EN 953


Combination of Guards & Protective Devices


• Guards must be suitable for purpose.

• Guards shall be constructed so as not to have

exposed sharp edges and corners or other

hazardous projections.

• Guards shall be designed to withstand reasonably

foreseeable impacts from parts of machinery,

workpiece, broken tooling, ejected solid or fluid

matter, impact by the operator, etc.

• Materials and finishes used shall be non-toxic in all

foreseeable conditions of use.

BS EN 953


Distance Tunnel Guard


• 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.

BS EN 953 Selection of guards


• Guards should be selected from the following in the

order of priority given:

c) Partial distance guard if the use of an enclosing

guard is impracticable and the number of danger

zones to protect is low.

d) Fully surrounding distance guard if the use of an

enclosing guard is impracticable and the number or

size of the danger zones are high.

BS EN 953 Selection of guards


Suitability of guards


• Climbing on guards shall as far as practicable be

inhibited by design. Consideration shall be given to

this possibility in their construction and the selection

of materials and shapes.

• By eliminating horizontal structural members and

the horizontal component of mesh fabric from the

outside surface of the guard, climbing is made more

difficult.

BS EN 953


• Colour

• Hazards can be highlighted by the use of suitable

colours. For example if a guard is painted the same

colour as the machine and the hazardous parts

painted a contrasting bright colour, attention is

drawn to the hazard when the guard is opened or left

off.

BS EN 953


Tel. +44 (0) 1642 345637

Fax +44 (0) 1642 345643

E-Mail: [email protected]

www.tuv-sud.co.uk

END

Documents

Power Point Template - TUV · PDF file–Safety related control systems – BS EN 13849/62061 ... EN 13849 . TÜV SÜD Product ... BS EN 12100- 2010