Safety in pneumatic automation
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1 Safety in pneumatic automation Pharm connect congress 2014 Budapest Feb Thomas Schulz Head of ISM and KAM Biotech/Pharma Phone: / Mail: Thomas Schulz / CP-KB Pharm connect congress Budapest
2 Safety in pneumatic automation Presentation 1. General information about Festo 2. Legal Regulations - Specifics for Factory- and Process-Automation 3. Risk analysis - risk assessment - risk reduction 4. Safety Functions Categories (input logic output) 5. Applications Increased safety for double acting valves defined safety position Increased safety for single acting valves quick exhausting Combined safety measures by pressure zones and quick exhaust valves Thomas Schulz / CP-KB Pharm connect congress Budapest
3 Festo an independent family-owned company Some Facts & Figures Pneumatic & Electric Automation Technology offering solutions for Factory & Process Automation Learning Systems, Training & Consulting Turnover 2,3 billion (2013) 61 international Festo companies Customers worldwide Components in countless variants Employees worldwide Festo Technology Centre and Headquarters, Esslingen, DE Festo Customer Service Centre and production plant, St. Ingbert, DE Investments in % of turnover: R&D: 7,0 % Training: 1,5 % Thomas Schulz / CP-KB Pharm connect congress Budapest
4 Legal regulation Risk assessment Laws e.g. EC Machinery Directive 2006/42/EC Safe machines Risk assessment Risk analysis Risk assessment Risk reduction Design measures Technical measures User information Standardized process + check list Evaluation and assessment of technical safety measures Safety function Input Logic Output Evaluation : PL PLr SIL SILr Risk reduction Evaluation whether risk reduction is sufficient Thomas Schulz / CP-KB Pharm connect congress Budapest
5 Risk Analysis Determininig the performance level a b c d e DIN EN ISO Appendix S Severity of injury S1 Slight /Normally reversible injury S2 Serious (normally irreversible injury, including death F Frequency and/or duration of exposure to the hazard F1 Seldom to less often or brief F2 Frequent to continuous and/or long P Possibility of avoiding the hazard P1 Possible under specific conditions F2 Scarcely ever possible a e Performance level PL Thomas Schulz / CP-KB Pharm connect congress Budapest
6 Signalling structure - categories Category B and Category 1 Input- Output- Input signal Logic signal Output Signal 1 channel Failures will not be detected 0 fault safety Category 1 uses only prooven components Thomas Schulz / CP-KB Pharm connect congress Budapest
7 Signalling structure - categories Category 2 Test signal Monitoring Input signal Output signal Input Logic Output Trigger signal Monitoring Logic Second path for shut down or indication Output Additional testing and monitoring failure detection possible 100x test of the function before the request by the machine control System No permanent fault monitoring 0 fault detection between the test phases Thomas Schulz / CP-KB Pharm connect congress Budapest
8 Signalling structure - categories Category 3 Monitoring Input signal Input Logic Output signal Output Input Input signal Test signal Logic Monitoring Output signal Output Signals via 2 channels Some, but not all faults are detected before or during the next request 1 Fault safety multiple undetected faults lead to the loss of Safety function Thomas Schulz / CP-KB Pharm connect congress Budapest
9 Signalling structure - categories Category 4 Monitoring Input signal Input Logic Output signal Output Input Input signal Test signal Logic Monitoring Output signal Output Signals via 2 channels Every fault must be detected before or during the next request 1 Fault safety Thomas Schulz / CP-KB Pharm connect congress Budapest
10 Signalling structure - categories Category B and Category 1 Category 3 Category 2 Category 4 Thomas Schulz / CP-KB Pharm connect congress Budapest
11 Risk Assessment PL vs. SIL Performance level PL Safety Integrity Level SIL MTTF d = Mean Time To Failure (dangerous) High Demand Mode max. failure a b c 1 d 2 e 3 Cat. B Cat. 1 Cat. 2 Cat. 3 Cat. 4 Probability of failure (per hour) Thomas Schulz / CP-KB Pharm connect congress Budapest
12 Applications - Plant and machine safety Machine directives and safety procedures request in many cases a safe shutdown of machines and process equipment in case of an emergency. To increase plant safety the following technical measures can be implemented: 1. Double acting valves (DA) Bring the valve to a defined position with the right pneumatic functions 2. Single acting valves (NC or NO) Quick exhausting of an emergency to prevent unintended actuation of a process valve due to back pressure and pressure peaks in the system 3. Application: Filling station for powder Combined safety measures by pressure zones on a valve terminal and quick exhausting Thomas Schulz / CP-KB Pharm connect congress Budapest
13 Increased safety for double acting valves defined safety position Double acting valves or cylinders have no defined safety position. In case of a shutdown or emergency this might cause a problem. A defined safety position can be integrated pneumatically by either holding the pressure in the actuator or exhausting it. Pressurizing Exhausting Thomas Schulz / CP-KB Pharm connect congress Budapest
14 Increased safety for double acting drives defined safety position Thomas Schulz / CP-KB Pharm connect congress Budapest
15 Increased safety for double acting drives defined safety position Double acting cylinder <Safety operation> <Compressed air + voltage available> Action : when applying compressed air, cylinder moves to safety position 1
16 Increased safety for double acting drives defined safety position Double acting cylinder <Safety operation> <Compressed air + voltage applied> Action : cylinder is forced into safety position 2
17 Increased safety for double acting drives defined safety position Double acting cylinder <Safety Operation> <Supply voltage ON, Step 1> Action : electromagnetic valve ON ( Enable ) 3 19
18 Increased safety for double acting drives defined safety position Double acting cylinder <Safety Operation> <Supply voltage ON, Step 2> Action : pneumatic valves ON ( Enable ) 4 20
19 Increased safety for double acting drives defined safety position Double acting cylinder <Safety Operation> <Cylinder positioning> Action : 5/3-valve move right 5 21
20 Increased safety for double acting drives defined safety position Double acting cylinder <Safety Operation> <Cylinder positioning> Action : 5/3-valve move left 6 22
21 Increased safety for double acting drives defined safety position Double acting cylinder <Safety Operation> <Supply voltage failure, Step 1> Action : supply voltage OFF 7 23
22 Increased safety for double acting drives defined safety position Double acting cylinder <Safety Operation> <Supply voltage failure, Step 2> Action : electromagnetic valve OFF 8 24
23 Increased safety for double acting drives defined safety position Double acting cylinder <Safety Operation> <Supply voltage failure, Step 3> Action : pneumatic valves OFF, cylinder moves to safety position 9 25
24 Increased safety for double acting drives defined safety position Double acting cylinder <Safety Operation> <Supply voltage failure, Step 4> Action : Cylinder is forced into safety position 10 26
25 Increased safety for single acting valves quick exhausting In case of an emergency single acting valves will fall back into their defined safety position. Normally the pneumatic system will remain under pressure. Accidently triggered pressure peaks might actuate a process valve possible risk Additional safety can be achieved by: o o Include a quick exhausting valve in the pneumatic system. In an emergency shut down the pneumatic system will be exhausted quickly. Include an integrated locking device for protection against unexpected start up Thomas Schulz / CP-KB Pharm connect congress Budapest
26 Increased safety for single acting valves quick exhausting The highest safety for this application can be reached e.g. with MS-6-SV-E or MS-6-SV-E-ASIS Cat. 4 PL e Diagnostic coverage Integrated, internal sensing of the piston position Channels 2 Certificate IFA Safety component to YES MD 2006/42/EC Thomas Schulz / CP-KB Pharm connect congress Budapest
27 Powder filling station System without pressure Zone 1 Zone 2 Open/close of powder supply Pressure build up and quick exhaust valve Redundant signal cable for quick exhaust valve Flexible bag holder and sealing Thomas Schulz / CP-KB Pharm connect congress Budapest
28 Powder filling station System under pressure and working Zone 1 Zone 2 Redundant signal cable for quick exhaust valve Thomas Schulz / CP-KB Pharm connect congress Budapest
29 Powder filling station System under pressure and working Zone 1 Zone 2 Emergency stop or signal missing Thomas Schulz / CP-KB Pharm connect congress Budapest
30 Powder filling station System partly under pressure and working Zone 1 Zone 2 1. Actuator for powder supply exhausting and closing 2. Bag holder and sealing still working Thomas Schulz / CP-KB Pharm connect congress Budapest
31 Powder filling station System partly under pressure and working Zone 1 Zone 2 1. Powder supply closed 2. Bag sealing still working Safe operation according to PL e possible Thomas Schulz / CP-KB Pharm connect congress Budapest
32 Further information Safety poster Safety engineering brochure Thomas Schulz / CP-KB Pharm connect congress Budapest
33 Contact Data Thomas Schulz Head of Key Account Management and Industry Segment Management Biotech/Pharma/Cosmetics +49 (0) Thomas Schulz / CP-KB Pharm connect congress Budapest
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