SARM-ANALYSIS for the BAGGAGE HANDLING SYSTEM NEW SEOUL INTERNATIONAL AIRPORT INCHON, SOUTH KOREA VERSION 3.0 Copy # 3 of 3 Prepared by : Responsibility Date Signature M+H Gesellschaft für Technische Beratung mbh D-70565 Stuttgart 26.09.2000 Approved by : Issued by : Mannesmann Dematic AG Systeme D-63073 Offenbach Mannesmann Dematic AG Systeme D-63073 Offenbach 26.09.2000 26.09.2000 SARM-Analysis
Contents Section 1 1 Introduction... 1 1 2 Safety... 2 1 2.1 General... 2 1 2.2 Basic Standards... 2 1 2.3 Definition of Risk... 2 2 2.3.1 General... 2 2 2.3.2 Boundary Risk... 2 3 2.3.3 Remaining Risk... 2 3 2.3.4 Probability of Damage... 2 3 2.3.5 Frequency and Duration of Exposure... 2 3 2.3.6 Extent of Damage... 2 3 2.3.7 Risk Assessment... 2 3 2.4 Risk Assessment and Safety Categories... 2 4 2.4.1 Description of Categories... 2 5 2.5 BHS Risk Assessment... 2 6 2.5.1 Definition of Risk (EN 1050)... 2 7 2.5.2 Required Equipment Category (EN 954)... 2 9 2.6 Recommendations... 2 11 2.6.1 General... 2 11 2.6.2 Emergency-Off Equipment... 2 11 2.6.3 Conveyor Equipment... 2 12 2.6.4 Personnel... 2 12 2.6.5 Recommended General Safety Documentation... 2 13 2.6.6 Recommended Maintenance Safety Documentaion... 2 27 3 ARM Calculations; Explanatory Remarks... 3 1 3.1 Methods... 3 1 3.2 Guide to the Data Sheets and Calculations... 3 2 3.3 Possible Interfaces and Interfering Factors... 3 4 3.3.1 Interfaces... 3 4 3.3.2 Interfering Factors... 3 5 Issued: Sept. 00 SARM-Analysis (of 7) page 1
Contents 4 Components... 4 1 4.1 Quantities of Components... 4 2 4.2 Straight, Metering and Inclined Belt Conveyors... 4 3 4.3 Check-In and Dispatch Belt Conveyors... 4 10 4.4 Merge Belt Conveyor 45... 4 15 4.5 Inclined Carousel... 4 17 4.6 Power Turn... 4 21 4.7 Diverter... 4 23 4.8 Hinge Mechanism... 4 27 4.9 High-Speed Pusher... 4 31 4.10 Low-Speed Pusher... 4 35 5 Summary... 5 1 6 The Availability of Functional Groups... 6 1 6.1 Out of Gauge Baggage... 6 1 6.2 Re-Check-In... 6 3 6.3 Domestic Departure... 6 9 6.4 International Departure... 6 12 6.4.1 Check-In Half Isle IND-E1... 6 12 6.4.2 Check-In Half Isle IND-E2 (Left)... 6 16 6.4.3 Check-In Half Isle IND-E2 (Right)... 6 20 6.4.4 Check-In Half Isle IND-E3 (Left)... 6 24 6.4.5 Check-In Half Isle IND-E3 (Right)... 6 28 6.4.6 Check-In Half Isle IND-E4... 6 32 6.4.7 Check-In Half Isle IND-W1... 6 36 6.4.8 Check-In Half Isle IND-W2 (Right)... 6 40 6.4.9 Check-In Half Isle IND-W2 (Left)... 6 44 6.4.10 Check-In Half Isle IND-W3 (Right)... 6 48 6.4.11 Check-In Half Isle IND-W3 (Left)... 6 52 6.4.12 Check-In Half Isle IND-W4 (Right)... 6 56 Issued: Sept. 00 SARM-Analysis (of 7) page 2
Contents 6.4.13 Check-In Half Isle IND-W4 (Left)... 6 60 6.4.14 CTB Check-In... 6 64 6.5 Arrival... 6 65 6.5.1 International... 6 65 6.5.2 Domestic... 6 78 6.6 Connection from Check-In to Final Sorter... 6 79 6.6.1 Collecting Line 1 East... 6 79 6.6.2 Collecting Line 2 East... 6 82 6.6.3 Collecting Line 1 West... 6 85 6.6.4 Collecting Line 2 West... 6 88 6.6.5 Connection Collecting Line 1 East Final Sorter East 1... 6 92 6.6.6 Connection Collecting Line 2 East Final Sorter East 2... 6 95 6.6.7 Connection Collecting Line 1 West Final Sorter West 1... 6 97 6.6.8 Connection Collecting Line 2 West Final Sorter West 2... 6 100 6.6.9 Crossover East West 1... 6 102 6.6.10 Crossover East West 2... 6 105 6.6.11 Crossover West East 1... 6 108 6.6.12 Crossover West East 2... 6 111 6.6.13 Manual Encoding; Final Sorters... 6 114 6.7 International Transfer... 6 116 6.7.1 East... 6 116 6.7.2 West... 6 124 6.8 Early Bag Storage... 6 132 6.8.1 Final Sorter East 1... 6 132 6.8.2 Final Sorter East 2... 6 136 6.8.3 Final Sorter West 1... 6 140 6.8.4 Final Sorter West 2... 6 143 6.9 Laterals... 6 147 6.9.1 East... 6 147 6.9.2 West... 6 152 Issued: Sept. 00 SARM-Analysis (of 7) page 3
Contents 7 Appendix... 7 1 7.1 List of Abbreviations and Acronyms... 7 1 7.2 Applicable Standards and References... 7 3 7.3 Sources... 7 4 8 List of References... 8 1 9 Free for User... 9 1 Issued: Sept. 00 SARM-Analysis (of 7) page 4
Figure Section 1 Section 2 Fig. 2 1: Definitions... 2 2 Fig. 2 2: Risk Assessment... 2 4 Section 3 Section 4 Fig. 4 1: Straight, Metering, and Inclined Belt Conveyors... 4 4 Fig. 4 2: Check-In and Dispatch Belt Conveyors... 4 10 Fig. 4 3: Merge Belt Conveyor 45... 4 15 Fig. 4 4: Inclined Carousel... 4 18 Fig. 4 5: Power Turn... 4 21 Fig. 4 6: Diverter... 4 24 Fig. 4 7: Hinge Mechanism... 4 28 Fig. 4 8: High-Speed Pusher... 4 32 Fig. 4 9: Low-Speed Pusher... 4 35 Section 5 Section 6 Section 7 Issued: Sept. 00 SARM-Analysis (of 7) page 5
Table Section 1 Section 2 Section 3 Section 4 Table 4 1: Maintainability Data... 4 5 Table 4 2: Belt Conveyor > 5 m... 4 6 Table 4 3: Maintainability Data... 4 7 Table 4 4: Belt-Conveyor < 5 m... 4 7 Table 4 5: Maintainability Data... 4 8 Table 4 6: Metering Belt-Conveyor... 4 8 Table 4 7: Maintainability Data... 4 9 Table 4 8: Inclined/Declined Belt Conveyor... 4 9 Table 4 9: Maintainability Data... 4 11 Table 4 10: Check-In Belt Conveyor... 4 12 Table 4 11: Maintainability Data... 4 13 Table 4 12: Dispatch Belt Conveyor... 4 14 Table 4 13: Maintainability Data... 4 16 Table 4 14: Merge Belt Conveyor 45... 4 16 Table 4 15: Maintainability Data... 4 19 Table 4 16: Inclined Carousel... 4 20 Table 4 17: Maintainability Data... 4 22 Table 4 18: Power Turn... 4 22 Table 4 19: Maintainability Data... 4 25 Table 4 20: Diverter... 4 26 Table 4 21: Maintainability Data... 4 29 Table 4 22: Hinge Mechanism... 4 30 Table 4 23: Maintainability Data... 4 33 Table 4 24: High-Speed Pusher... 4 34 Table 4 25: Maintainability Data... 4 36 Table 4 26: Low-Speed Pusher... 4 37 Section 5 Section 6 Table 6 1: Out of Gauge Baggage... 6 2 Table 6 2: Re-Check-In... 6 8 Table 6 3: Domestic Departure... 6 11 Table 6 4: International Departure; Check-In Half Isle IND-E1... 6 15 Issued: Sept. 00 SARM-Analysis (of 7) page 6
Table Table 6 5: International Departure; Check-In Half Isle IND-E2 (Left)... 6 19 Table 6 6: International Departure; Check-In Half Isle IND-E2 (Right)... 6 23 Table 6 7: International Departure; Check-In Half Isle IND-E3 (Left)... 6 27 Table 6 8: International Departure; Check-In Half Isle IND-E3 (Right)... 6 31 Table 6 9: International Departure; Check-In Half Isle IND-E4... 6 35 Table 6 10: International Departure; Check-In Half Isle IND-W1... 6 39 Table 6 11: International Departure; Check-In Half Isle IND-W2 (Right)... 6 43 Table 6 12: International Departure; Check-In Half Isle IND-W2 (Left)... 6 47 Table 6 13: International Departure; Check-In Half Isle IND-W3 (Right)... 6 51 Table 6 14: International Departure; Check-In Half Isle IND-W3 (Left)... 6 55 Table 6 15: International Departure; Check-In Half Isle IND-W4 (Right)... 6 59 Table 6 16: International Departure; Check-In Half Isle IND-W4 (Left)... 6 63 Table 6 17: International Departure; CTB Check-In... 6 64 Table 6 18: Arrival; International... 6 77 Table 6 19: Arrival; Domestic... 6 78 Table 6 20: Collecting Line 1 East... 6 81 Table 6 21: Collecting Line 2 East... 6 84 Table 6 22: Collecting Line 1 West... 6 87 Table 6 23: Collecting Line 2 West... 6 91 Table 6 24: Connection Collecting Line 1 East Final Sorter East 1... 6 94 Table 6 25: Connection Collecting Line 2 East Final Sorter East 2... 6 96 Table 6 26: Connection Collecting Line 1 West Final Sorter West 1... 6 99 Table 6 27: Connection Collecting Line 2 West Final Sorter West 2... 6 101 Table 6 28: Crossover East West 1... 6 104 Table 6 29: Crossover East West 2... 6 107 Table 6 30: Crossover West East 1... 6 110 Table 6 31: Crossover West East 2... 6 113 Table 6 32: Manual Encoding; Final Sorters... 6 115 Table 6 33: International Transfer; East... 6 123 Table 6 34: International Transfer; West... 6 131 Table 6 35: Early Bag Storage; Final Sorter East 1... 6 135 Table 6 36: Early Bag Storage; Final Sorter East 2... 6 139 Table 6 37: Early Bag Storage; Final Sorter West 1... 6 142 Table 6 38: Early Bag Storage; Final Sorter West 2... 6 146 Table 6 39: Laterals; East... 6 151 Table 6 40: Laterals; West... 6 156 Section 7 Issued: Sept. 00 SARM-Analysis (of 7) page 7
1 Introduction M+H has been requested by MDC to carry out a SARM (Safety, Availability, Reliability, Maintainability) analysis of the components to be used for the BHS installed in Inchon International Airport. This installation is a belt conveyor system. Our initial goal is the analysis of system components as 'stand-alone units' with the assistance of the relevant technical drawings, lists of the electrical parts for each unit, and the experience and estimates of engineers fully conversant with the MDC designs. This first step is to intended to designate those parts having major relevance for the reliability of each component, determine the respective SARM figures for these parts and thus calculate the relevant figures for each component. In a second step, the stand-alone units are combined to functional groups. These functional groups consist of one or more conveyors in combination for one specific task, i.e. if one conveyor of the functional group is defective, the whole group is out of service. As a further step, the SARM analysis has to be extended to the whole system. The mutual interactions between the functional groups and layout redundancies for baggage transport will be considered at this time. This will also include SARM for the control software of the BHS. Accurate statements with regard to maintainabilty can only be made after completion of the relevant technical documentation (maintenance and repair). It should be noted that the maintainability of equivalent conveyors differ considerably due to their installed locations. These effects on maintainability cannot be taken into account, as this would presuppose a detailed, on-site investigation of the whole plant. Such an investigation would last at least several weeks. The results of the analysis are also intended as reference data for the internal use of the MDC Engineering Departments in the design and implementation of future projects. Version: Section 1 Issued: Sept. 00 SARM-Analysis (of 1) page 1
2 Safety 2.1 General The following section considers the various aspects of safety required to ensure the protection of persons and property (including facility equipment) against injury and damage during operation of the Baggage Handling System to be installed at Inchon International Airport. Aspects to be considered include the physical shielding and characteristics of equipment together with the provision of an adequate emergency-off system. The overall direction followed in the matters to be discussed is defined by the maxim of: Maximum Safety at Maximum Availability 2.2 Basic Standards The fundamental standards and guidelines requiring consideration are those currently valid in the European Community: EN 292; 'Safety of Machinery' EN 1050; 'Risk Assessment of Machines' EN 954; 'Safety-Related Parts of Control Systems' The EN 292 was compiled to assist designers, manufacturers and other interested parties in the interpretation of fundamental safety requirements. It defines a 'machine' as a combination of interconnected parts or devices, at least one of which is a moving part, with drive elements, control and power circuits for particular purposes of use. The EN 1050 sets general guidelines for the procedure of risk assessment and defines the information necessary for the performance of a risk assessment. The standard also defines the meaning of various terms, including 'risk' and 'risk assessment'. The EN 954 combines the 'machine risks' (based on the definitions in the EN 1050) with the equipment required to cope with and minimize these risks. It contains technical requirements and information for the configuration of safety-relevant parts of control systems, and defines categories with descriptions of the properties of the safety functions. Version: Section 2 Issued: Sept. 00 SARM-Analysis (of 28) page 2
2.3 Definition of Risk 2.3.1 General The basic terminology for the definition of risk is laid down in EN 1050: 'Boundary risk' 'Remaining risk' 'Probability of damage' 'Frequency and duration of exposure' 'Extent of damage 'Risk assessment' Fig. 2 1: Definitions Version: Section 2 Issued: Sept. 00 SARM-Analysis (of 28) page 3
2.3.2 Boundary Risk The boundary risk is defined as the 'maximal acceptable risk' of a technical process or condition. 2.3.3 Remaining Risk Any (acceptable) technical solution with regard to the safety of a machine or system will minimize the risk to a lower level than the boundary risk. However, there will always be a residual level of risk remaining risk whenever the relevant 'machine' is in use. 2.3.4 Probability of Damage The probability of possible damage will depend on several factors. One fundamental factor is, obviously, the type of 'machine' or technical system in question. The probability of damage occurring during use of, for example, a chain saw is considerably higher than that occurring during use of a pin-wheel printer. Additional factors are the type of use (e.g. direct hand-held usage of a drill or the remote control of a crane), the duration and/or frequency of use and also the area in which the machine or system is installed. 2.3.5 Frequency and Duration of Exposure According to the type of system, consideration has also to be given to frequency and duration of contact of persons interacting with the machine or system. 2.3.6 Extent of Damage The extent of possible damage also has to be taken into consideration : Type of protected interest: Persons Objects Environment Severity: Slight, reversible Severe, irreversible Deadly Range of damage: One person Several persons 2.3.7 Risk Assessment The system described has to investigated for a combination of risk factors. For example: Severe injury possible with Frequent access of persons to the risk area Version: Section 2 Issued: Sept. 00 SARM-Analysis (of 28) page 4