Practical Machinery and Automation Safety for Industry

THE WORKSHOP

Safety regulations are now well established in industry but in many cases companies are taking inadequate measures laying themselves and their staff open to prosecution. And on the other hand many companies are taking safety measures to protect their staff; but are wasting a considerable amount of money in achieving ineffective partial compliance with the relevant standards and regulations. This workshop’s main aim is to provide you with the tools to comply with the Safety legislation and ensure that your staff are

This workshop familiarises you with a wide variety of machinery hazards and shows  you methods of making your equipment safe and complying with the applicable local safety Laws. Practical topics on this workshop range from safeguarding of machinery, the Occupational Health and Safety Act, Safety Control Systems to Safe Fieldbus technology. This workshop focuses on giving you the tools to apply the principles of Machinery Safety to real equipment and systems. Practical case studies are a key part of the course to ensure that you get a real world practical exposure to the topic.

The workshop commences with a clear discussion of the various legal requirements for safe machinery use and operation. Design procedures for safety controls are then explained with a set of rules for risk assessment and risk reduction principles and the applicable standards. Methods for identifying hazards and hazard study methods form the next topic. An introduction to machinery protection devices such as guards, enclosures with interlocks and guard monitoring relays, locking systems, safety mats, photo electric and electro sensitive principles, light curtains, proximity sensors are then assessed. The second day is commenced with a study of Safety Control System techniques and Programmable Controllers focussing on practical useful information you can apply to your next project. Application examples such as guard door interlocking applications, power press applications, area protection of robot installations and motion detection are then discussed. The course is then completed with a study on Machinery Safety Management and a useful checklist is provided when you next audit your plant.

WHAT IS INCLUDED?

  • Receive a certificate of attendance in support of your continuing professional commitment
  • All workshops include the associated hardcopy technical manual
  • Printed workshop handouts
  • Lunch and refreshments
  • Interact and network with workshop attendees and experienced instructors
  • Practical, industry driven content to assist you in your continuing professional development (CPD)
  • Attendees automatically become IDC subscribers and receive exclusive deals and technical content every month

WHO SHOULD ATTEND?

  • Automation engineers
  • Compliance engineers
  • Consulting engineers
  • Control engineers and technicians
  • Design engineers
  • Designers
  • Electrical engineers
  • Electronic engineers and technicians
  • Instrumentation and control engineers/technicians
  • Machinery designers, system integrators
  • Process control engineers
  • Process engineers
  • Production managers
  • Safety professionals, health and safety officers
  • Systems engineers
  • System integrators
  • Test engineers

CONTENT SUMMARY

COURSE OBJECTIVES AND INTRODUCTION TO MACHINERY

SAFETY PRINCIPLES

  • Course outline and objectives
  • Definition of a machine and the scope of machinery controls
  • Examples of common hazards and typical safety system solutions
  • Applicable standards and sources of information

REGULATIONS FOR MACHINERY SUPPLY AND END USE

  • Regulations for supply of machinery (Safety), European (CE) and USA examples
  • Regulations for the safe use of machinery at work. EC and USA examples
  • The European Machinery Directive - its scope, implications and outline requirements
  • Discussion on end user practices and employer’s obligations

Practical exercise 1: Checkout a machine example for compliance

DESIGN PROCEDURES FOR SAFETY CONTROLS

  • Background to safety life cycle practices and explanation of the major steps in design of safety systems
  • Risk assessment and risk reduction principles
  • Measures for risk reduction
  • Specification of safety requirements
  • Explanation of equipment safety categories
  • Introduction to applicable standards: EN 1050 and EN 954

Practical exercise 2: Evaluate an example for category of  protection function

RISK ASSESSMENT AND HAZARD STUDY METHODS

  • Methods for identifying hazards, Machinery concept hazard analysis, activity analysis, human error analysis
  • Practical example of hazard study
  • Risk assessment and the selection of protection measures
  • Explanation of safety categories
  • Examples of selection of safety categories using EN 954
  • Introduction to safety integrity levels

Practical exercise 3: Trial hazard study and selection of safety categories

MACHINERY PROTECTION DEVICES: INTRODUCTION

  • Guards and enclosures with interlocks
  • Fixable and moveable guards
  • Users responsibility
  • Emergency stops and guard interlocking
  • Guard monitoring relays
  • Locking systems
  • Safety mats
  • Photo-electric and electro sensitive principles
  • Light curtains and proximity sensors
  • Instructions, warnings and labels
  • Evaluation of approach speeds, safety distances and times

Practical exercise 4: Application examples, selection of devices

SAFETY CONTROL SYSTEM TECHNIQUES

  • Principles of  Safety Related Control Systems
  • Introduction to IEC 61508 general standard for functional safety
  • Subsystems: sensor, logic solver, final control element
  • Principles of separation and fault tolerance
  • Reliability requirements, fail safe principles
  • Diagnostics and self testing methods
  • Safety relays, emergency-stop relays
  • Circuit application examples for categories 1 to 4

Practical exercise 5: Design task, application of safety relays

PROGRAMMABLE SYSTEMS

Why regular PLCs should not be used for safety functions

  • Programmable electronic logic solvers
  • Safety Certification
  • Certified programming systems
  • Application examples
  • Growth of networked safety devices and certified networks
  • Integrated safety systems

APPLICATION EXAMPLES

  • Guard door interlocking applications; examination of circuits and operating principles
  • Power press application with light curtain.
  • Area protection of robot installations.
  • Motion detection with run down protection system

Practical exercise 6: Maintenance proof testing of a typical application

MACHINERY SAFETY MANAGEMENT

  • Maintenance practices and issues on existing plant
  • Practical exercise: checklist for safety compliance
  • Ways to deal with existing machinery needing a safety upgrade
  • Evaluation of new machinery compliances

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