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A Practical Guide To Machinery Safety Edition 4 PDF
A Practical Guide To Machinery Safety Edition 4 PDF
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Contents Sponsors
section one
TÜV SÜD Product Service 05
Laidler Associates 05
Safety Systems 05
Case Studies 06
section two
Machinery & EMC Directives 10
Machinery Safety is one of the most significant Low Voltage & Pressure Equipment Directive 11
issues facing every manufacturing company in ATEX & Work Equipment Directive 12
Europe today. It’s just as important as productivity EN Standards & Maritime Specifics 13
and is essential for the well being of everyone
section three
Risk Assessments
involved.
Issues to consider when assessing machinery safety 16
Hazard Identification 17
The Laidler group of companies has come together Safety Related Control Systems 18
to provide this practical guide to the field of Common Hazards 22
machinery safety, basing it around common
The 4 steps to CE Marking for the Machinery Directive
section four
hazards and issues that they come across on a
EHSRs 24
regular basis.
Technical File 25
Declaration and CE Mark 26
The aim of this guide is to introduce machinery Project Management 27
safety and provide suggestions and guidance as to
EMC Solutions
section five
the best route to compliance. Crucially though, it is
only a guide and an interpretation of the Mains Filters 31
Cables 31
regulations. The onus is placed firmly on the
Guidelines for installing Servodrives 32
machine manufacturer and user to show
compliance with all relevant legislation.
The Provision of use of Work Equipment Regulations
section six
Regulation 6: inspection 34
Regulations 10 - 24 35
section seven
Pre-Purchase Audit
Background and PUWER 38
The Solution 38
What to look at 39
External Assistance 39
section eight
Engineering Services
Engineering Design 42
Electrical Engineering 43
Machine Guarding 43
Products 45
Appendices
section nine
Attending our FREE Interactive Safety Workshop is an excellent way of finding out about current
and future legislation and guidelines as well as discovering the best safety solutions on the market.
Seminar Agenda
• CE Marking and PUWER regulations • Current and forthcoming legislation
• EN Standards and their affect on industry • Risk Assessment and it's implications
• Case Studies • Safety Related Control Systems
• Discussion with a full Q&A session
section one
Sponsors
Safety Systems
Technology
Sponsors
TÜV SÜD Product Service is a leading Laidler Associates is part of the machinery Safety Systems is part of the machinery division
international expert in providing testing, division of TÜV SÜD Product Service and is the of TÜV SÜD Product Service, and provides
certification, training and consultancy services UK market leader in machinery safety, which engineering services to ensure machinery
to a range of industries covering the Aerospace, covers machinery safety legislation and risk compliance, including full engineering project
Defence, Machinery, Marine, Medical & Health, assessments providing solutions on a world- management of compliance solutions bespoke
Radio & Telecoms, Rail, Trade, Electronics & wide basis. Laidler Associates provides guarding and safety product sales. As market
Consumer sectors. comprehensive, cost effective and supremely leaders in machinery safety compliance
practical consultancy, advisory, training, engineering, we have the knowledge and
• Testing seminars, project management and custom experience to design and install the most
• EMC software services in the following key areas: appropriate safety solutions using products from
• Environmental our wide ranging portfolio from leading
• Radio • CE Marking manufacturers. Services include:
• Safety • Machinery Directive
• Payment Systems • Low Voltage Directive • Project Definition and Design Studies
• Certification • Electromagnetic Compatibility • Multidiscipline Project Management
• Notified Body services under many (EMC) Directive • System Specification and Design
EU Directives • Pressure Equipment Directive • Electrical Design and Build Including
• GS Mark • ATEX Control Circuits
• TÜV SÜD Mark • Pre-Purchasing CE Audits • Guarding Design
• CB Scheme • Project Management of Complex • Commissioning and Installation
• NRTL Machinery Installation • Ongoing Support and Training
• Management Systems • Equipment Safety Audits • Modifications to Ensure Legal Compliance
• Training • Provision and Use of Work Equipment • ESPE (light curtain) Assessment
Regulations (PUWER)
• Electromagnetic Field Testing
• Risk Assessment
• SEMI
• Lifting Operations and Lifting Equipment
Inspections (LOLER)
• Training and University Courses
section one
Case
Studies
Case Study Its market potential was, therefore, excellent and was still
Laidler helps Proven Energy to prove compliance further boosted when the P35-2 became the first small wind
In line with its commitment to developing and supplying turbine to be awarded full certification under the
products that are confirmed as meeting the highest Microgeneration Certification Scheme (MCS).
standards for safety and performance, Proven Energy, the Understandably, Proven Energy was eager to put the P35-2
UK’s largest supplier of small wind turbines, decided that on sale at the earliest possible date.
they needed assistance with the self-declaration of their
latest P35-2 12.1 kW wind turbine to the new European By the beginning of 2010, it had the compliance work
Machinery Directive. Accordingly, the company engaged associated with the Low Voltage and EMC Directives in
leading safety and compliance consultant Laidler place but, for the Machinery Directive, things were a little
Associates, part of the Machinery division of TÜV SÜD more complicated. This was because a new version
Case Studies
Product Service, to help with completing the compliance (2006/42/EC) of the Machinery Directive came into force late
procedure including the preparation of the technical file. in December 2009. As no transition period between this and
the previous version of the Machinery Directive was
As a well established manufacturer of wind turbines, allowed, it was essential for Proven Energy to be sure that
Proven Energy was well aware that it could satisfy the CE its P35-2 wind turbine complied fully with the new version.
marking requirements in relation to its products by self-
declaring them for compliance with the EMC, Low Voltage
and Machinery Directives. The company decided, however,
that due to the changes to the requirements with the new
Machinery Directive, it would be prudent to have
assistance which would give both them and their end users
the highest possible level of confidence.
Case Studies
Associates, and organised our compliance documentation
in the way that the company suggested, we can have total
confidence that the P35-2 satisfies the requirements of the
latest version of the Machinery Directive,” said Jonathan
Nowill. “Naturally, this is very important for us but it’s also
important for our customers – they don’t have to take our
word for it that our products meet all of the relevant
standards, as this has now been independently confirmed.”
A further endorsement of the work carried out by Laidler
Associates for Proven Energy was recently provided by the
Health and Safety Executive (HSE).
Case Study so that the CE marking could be applied. For help in achieving
Smoothing the way for Minima to boost this, the company approached Laidler Associates.
office recycling
Full compliance with EU requirements was essential for the An initial assessment quickly showed, however, that it was
success of a novel can and plastic bottle compactor by no means certain which directives were applicable.
developed by Minima Eco for use in offices, but the Although the Minima Office is undeniably a machine,
requirements for achieving compliance were far from clear. Machinery Directive 2006/42/EC explicitly excludes “ordinary
However, Laidler Associates, one of the UK’s foremost office machinery”, so the question arose as to whether the
safety and compliance consultants, provided Minima Eco new Minima Office would fall within this definition.
with a complete, efficient and cost-effective solution.
To obtain a definitive answer to this question, Laidler
Case Studies
section two
Legislative
Framework
1. An assembly fitted with or intended to be fitted with a substituted in order for the machinery to function.
drive system other than directly applied manual or animal
effort, consisting of linked parts or components , at least The New Approach Directives lay down minimum criteria
one of which moves, and which are joined together for a for compliance. These criteria are called The Essential
specific application Health and Safety Requirements (EHSR).
2. Machinery referred to in 1 missing only the The preferred way to comply with EHSRs is by Risk
components to connect it on site or to sources of energy Assessment and the application of harmonised EN
and motion. standards, which are replacing the national standards of
member states.
3. Lifting apparatus whose only power source is directly
applied manual effort. EMC Directive
Scope
4. An assembly of machines and / or partly completed The EMC Directive states that most electrical and
machinery which, in order to achieve the same end are electronic products made or sold in Europe must:
arranged and controlled to function as an integral whole.
• Be so constructed that they do not cause excessive
5. Interchangeable equipment means a device which, electromagnetic interference and are not duly affected
after placing into service with machinery or tractor is by electromagnetic interference,
assembled with that machinery or tractor by the operator
himself in order to change its function. • Carry CE Marking
section two
If your product is sold, used by yourself, given away or used • The product has been designed and constructed in
in anyway, it must comply with the Essential Protection accordance with the Principal Elements of the Safety
Requirements as laid down in the Directive. Ignorance of Objectives of the Directive.
the legislation is no excuse and a punitive penalty structure
is documented. Electrical equipment shall be designed and constructed to
ensure that it is safe when connected to the electricity
The requirements under the EMC Directive are: supply, by providing a level of protection against electric shock.
• That the product must not interfere with any other Pressure Equipment Directive
product in any way. Scope
The Pressure Equipment Directive (PED) 97/23/EC which
ATEX Directive assessment and provide work equipment that is suitable for
The "ATEX" Directive 94/9/EC is a so-called "New Approach" its intended task and can be used without putting persons
Directive which provides the technical requirements to be at risk.
applied to equipment intended for use in potentially
explosive atmospheres. It is named after the French The Regulations cover any machinery, appliance,
"ATmosphere EXplosible". apparatus, tool or installation for use at work (whether
exclusively or not) - effectively it is anything used at work.
The Directive covers a surprisingly large range of The 1998 regulations (updating the original 1992
equipment, potentially including equipment used on fixed Regulations) introduce requirements to ensure that, for
offshore platforms, in petro-chemical plants, mines, flour reasons of health and safety, inspections are carried out:
mills and other areas where a potentially explosive
Legislative Frame Work
atmosphere may be present. • After installation and before being put into service for
the first time; or after assembly at a new site or in a new
In very broad terms, there are three pre-conditions for the location to ensure that it has been installed correctly
Directive to apply: and is safe to operate.
• The equipment must have its own source of ignition • After work equipment has been exposed to any
conditions causing deterioration, which is liable to
• Be intended for use in a potentially explosive cause a dangerous situation.
atmosphere (air mixtures)
• At suitable intervals; and
• Be under normal atmospheric conditions.
• Each time that exceptional circumstances have
The Directive also covers components essential for the safe occurred that are liable to jeopardise the safety of work
use and safety devices directly contributing to the safe use equipment. The results of these inspections have to be
of the equipment in scope. These latter devices may be documented and kept.
outside the potentially explosive environment.
The regulations make it an offence to allow work
Work Equipment Directive equipment to leave an employer’s undertaking, or if
Scope obtained from another undertaking, be used, unless it is
The Provision and Use of Work Equipment Regulations 1998 accompanied by physical evidence that the last inspection
(PUWER) requires users of work equipment to carry out risk has been carried out.
section two
EN Standards Maritime specifics
By definition a standard is "A document established by November 2006 saw a major change with PUWER. Up to this
consensus and approved by a recognised body, that date, work equipment on ships was outside of the scope of
provides, for common and repeated use, rules, guidelines or PUWER because there were other maritime regulations that
characteristics for activities or their results aimed at the took precedence (these have now been revoked). In
achievement of the optimum degree of order in a given September 2006, a new maritime version of PUWER was
context" (ISO/IEC guide 2 (1986). published. The Merchant Shipping & Fishing Vessels
(Provision & Use of Work Equipment) Regulations 2006
Three organisations are mandated by the European impose the minimum health and safety requirements for the
Commission to produce standards, with each organisation provision and use of work equipment by workers at work.
being responsible for specific standards.
Machinery Safety
CE Marking, PUWER & Practical Risk Assessments
Courses all across the country, so book you place now by calling
+44(0)1642 345637 or emailing us at enquire@laidler.eu
section three
Risk
Assessment
Risk Assessment
many places. EN ISO 12100 is the main standard for risk
assessment for machinery as it sets down the principles for
the process. Hazard Identification
Risk assessment is fundamental to any health and safety EN ISO 13849-1
process and in particular machinery safety. Because of this,
anyone involved in dealing with machinery safety issues
should be competent in risk assessment and be well aware EN ISO 12100
of the types of hazards that may occur across their working
environment. EN 62061
Risk Assessment is subjective therefore the information in
this section gives help and advice on risk assessment. It has Common hazards
to be stressed that it is only a guide and the onus remains
firmly with the person carrying out the assessment to comply
with all the relevant regulations.
• Are they fitted correctly? • Does the machinery fall under • Is there adequate lighting? • Is the enclosure locked? • Is guarding fitted?
the Machinery Directive?
• Do they all work correctly? • Is the floor area free from slip • Are all enclosures fitted with • Is it adequate?
• Have all the Directives been and trip hazards? electrical warning signs?
• Are they accessible? considered i.e. EMC, Low • Are interlocks fitted where
Voltage, ATEX and PED? • Are they free from debris and required and are they positively
• Are they correct type? foreign objects? acting?
• If so, has it been CE Marked?
• Do fixed guards require tools
• Has it been altered in a way for their removal
that could affect the original
CE Marking?
section three
Hazard Identification Risk Assessment Objective
A hazard is: To achieve adequate safety according to the state of the art
Anything that has the potential to do harm, a source of and technical and economic requirements. There are
possible injury or damage to health. numerous ways of assessing risk involved with a hazard,
A risk is: one of which is the hazard rating number system. (HRN).
The likelihood of someone coming into contact with a The practical risk assessment method that is used by
hazard and the degree of injury or damage to health that Laidler Associates is Preliminary Hazard Analysis, which
could be caused should contact occur. uses the HRN system. A sample risk assessment form can
A hazardous situation is: be found in the appendices at the end of this guide.
Any situation where a person or persons are exposed to a
hazard. Numerical values are assigned to descriptive phrases
Risk Assessment
relating to-
Examples:
A moving belt on a conveyor would be a hazard. The risk • The likelihood of occurrence (LO)
would be the likelihood of someone coming into contact with • The frequency of exposure (FE)
an in-running nip or being drawn along the belt by a protrusion • The degree of possible harm (DPH)
and the severity of injury or damage to health that could be • The number of persons at risk (NP)
caused. An electrical enclosure containing voltages above 50v
AC and 75v DC that has uncovered terminations is a hazard A key to the number system is detailed on the risk
even though the enclosure may be kept locked and strict key assessment form in the appendices.
control enforced. The reason for this is that if an electrician
had to carry out diagnostic testing on a live enclosure they The hazard description is vital in understanding those risk
could inadvertently touch an adjacent terminal with a tool etc. assessments, unless otherwise stated, the risk assessment
The risk would be the likelihood of that happening and the relates to the hazards in the normal operation of the
severity of injury or damage to health that could be caused. machine. Where a specific risk is associated with that
equipment, a separate risk assessment will be provided.
Risk Assessment Definition
A comprehensive estimation of the probability and degree Where there is no control over the frequency of exposure, a
of possible injury or damage to health in a hazardous worst-case scenario must be assumed, and a constant
situation in order to select appropriate safety measures. frequency is assigned.
Risk Assessment Example effectively tie your hands. Our assessments are one method of
Injury due to access to dangerous parts of machinery. The compliance and should you find an alternative way to achieve
present guarding, partially fitted, allows access to the compliance, then we would welcome your suggestions. Our
moving parts. engineers are available to give specific advice to you outside
of these assessments should you require it.
LO FE DPH NP=H.R.N.
2 X 5 X 4 X 1=40 As mentioned at the start of this section, EN ISO 12100 is the
Degree of risk: = Significant main standard for risk assessment for machines and is
harmonised to the Machinery Directive. It lays down
Clearly from this example we can see that the existing principles for risk assessment, hazard analysis and
guarding, whilst offering a certain amount of protection, is documentational requirements.
Risk Assessment
section three
Safety Related Control Systems BS EN ISO 13849-1
What is a control system? Provides safety requirements and guidance on the
A control system responds to input signals from the machine principles for the design and integration of safety-related
or from the operator and generates output signals. These parts of control systems, including the design of software.
make the machine operate in a desired manner. So if for For these parts of safety-related parts of control systems, it
example, an operator presses a start button then the control specifies characteristics that include the performance level
system may respond by closing a contactor and energising a required for carrying out safety functions. It applies to
motor. Control systems can be implemented in a range of safety related parts of control systems, regardless of the
technologies, but this guidance is mostly concerned with type of technology and energy used (electrical, hydraulic,
electro technical systems employing electrical, electronic pneumatic, mechanical, etc.), for all kinds of machinery.
and programmable electronic technologies. Electro technical
Risk Assessment
control systems can range from simple electromechanical It applies to safety-related parts of control systems,
relay based systems to complex programmable systems with regardless of the type of technology and energy used
multiple analogue and digital inputs and outputs. (electrical, hydraulic, pneumatic, mechanical, etc.), for all
kinds of machinery. Part 1 of BS EN ISO 13849 provides
What is a safety related control system? specific requirements for safety-related parts of control
A control system in a machine should be regarded as being systems using programmable electronic system with
safety-related if it contributes to reducing the occurrence of a guidance on aspects such as categories or performance
hazardous situation or if it is required to function correctly to levels specification. This part of ISO 13849 is intended to give
maintain or achieve safety. The functions carried out by a guidance to those involved in the design and assessment of
safety-related control system are termed safety functions. control systems. As part of the overall risk reduction strategy
Generally safety functions either prevent the initiation of a at a machine, a designer will often choose to achieve some
hazard or detect the onset of a hazard. Safety-related control measure of risk reduction through the application of
systems should be designed and configured to be reliable safeguards employing one or more safety functions.
enough (bearing in mind the consequences of any failure) and
to perform the necessary functions to achieve or maintain a Parts of machinery control systems that are assigned to
safe state or mitigate the consequences of a hazard. provide safety functions are called safety-related parts of
control systems and these can consist of hardware and
To assist a designer or assessor in deciding which of the software and can either be separate from the machine
two main standards to use: BS EN ISO 13849 or BS EN 62061, control system or an integral part of it. In addition to
a distinction is drawn between those electro technical providing safety functions, safety related parts of control
safety related systems that use programmable technologies systems can also provide operational functions (e.g. two
and those that use electromechanical components. handed controls as a means of process initiation).
In order to assist the designer and help facilitate the Which standard now?
assessment of achieved PL, this document employs a When evaluating which standard to use, it is important to
methodology based on the categorisation of structures take into consideration the type of complexity that the
according to specific design criteria and specified equipment with the safety-related parts of control system
behaviours under fault conditions. has. The table below gives some indication of the
technologies which are covered by each standard. A
BS EN 62061 correct implementation of a safety-related parts of control
Is a harmonised standard for the machinery sector and system may require the application of both standards.
implements the principles of BS EN 61508. Significantly for
control systems designers and systems integrators, BS EN
62061 provides the basis for the successful integration of
Risk Assessment
section three
Table From IEC 62061
Technology implementing Note 1:
the safety-related control ISO 13849 IEC 62061 Designated
function(s) architectures are
defined in Annex b of
Non-electrical, e.g. EN ISO 13849-1 to give
A
hydraulics
3 Not covered
a simplified approach
for quantification of
performance level.
Electromechanical, e.g. Restricted to designated All architectures and
Risk Assessment
B relays,and/or non complex architectures (see Note 1) up to SIL 3
electronics and up to PL=e
Note 2:
Restricted to designated For complex
Complex electronics, e.g. All architectures and
C architectures (see Note 1)
programmable up to SIL 3 electronics. Use of
and up to PL=d
designated
architectures
Restricted to designated according to EN ISO
D A combined with B architectures (see Note 1) 3 See Note 3 13849-1 up to PL=d or
and up to PL=e any architecture
according to IEC 62061
Restricted to designated
All architectures and
E C combined with B architectures (see Note 1)
up to SIL 3
and up to PL=d
Note 3:
for non-electrical
C combined with A, or C
F
combined with A and B
3 see Note 2 3 see Note 2 technology, use parts
according to EN ISO
13849-1 as subsystems
A B
The 4 Steps to
section four
CE Marking for the
Machinery Directive
section four
CE Marking for the
Machinery Directive
Step 1: The Essential Health and Safety The 2006/42/EC Directive made changes to a number of the
Requirements (EHSRs) EHSRs. Some of the more significant changes are as follows:
In order to comply with the Supply of Machinery (Safety)
Regulations, the machinery must be able to satisfy the EHSRs • EHSR 1.1.7 The operating position must be designed to
for any corresponding hazard which may apply to it. Typical avoid any risk due to exhaust gases/ lack of oxygen
examples of Essential Health and Safety Requirements are • EHSR 1.1.8 work stations that are an integral part of the
the requirements to provide adequate warning marks where machine must be designed for the installation of seating
there are moving parts that might trap parts of the body of • EHSR 1.2.2 Manual controls must be clearly visible and
personnel using the machine. Another item would be the identifiable; the use of pictograms is recommended
requirement to provide safety guards to machine tools. • EHSR 1.4.2.1 Fixed guards. Fixing systems must remain
attached to the guards when removed
The 4 Steps to CE Marking for the Machinery Directive
The requirements are wide ranging, taking into account • EHSR 1.1.2 requires risk assessment to be carried out
potential dangers to operators and other persons who may be
at risk. The Essential Health and Safety Requirements are Risk assessment is the fundamental starting point for designers
mandatory. However, taking into account the state of art, it may of machinery under the Machinery (Safety) Regulations as well
not be possible to meet all the objectives set by them. With this as for operators of existing machinery under the Provision and
in mind, the machinery must be designed and constructed with Use of Work Equipment Regulations 98.
the purpose of approaching these objectives. Within the Supply
of Machinery (Safety) Regulations, the Essential Health and The standard EN ISO 12100 entitled “Safety of Machinery –
Safety Requirements are divided into six sections: Risk Assessment” defines risk assessment as “a series of
logical steps to enable, in a systematic way, the analysis
1. EHSRs applicable to all machinery and evaluation of the risks associated with machinery.”
2. EHSRs for Certain categories of machinery including
Foodstuffs machinery, machinery for cosmetics or EN ISO 12100 goes on; “Risk assessment is followed,
pharmaceutical products, hand-held and/or hand-guided whenever necessary, by risk reduction. Iteration of this
machinery, portable fixing and other impact machinery, process can be necessary to eliminate hazards as far as
machinery for working wood and material with similar practicable and to adequately reduce risks by the
physical characteristics implementation of protective measures.”
3. EHSRs to offset hazards due to the mobility of machinery
4. EHSRs to offset hazards due to a lifting operation To assist manufacturers comply with the Directives and to
5. EHSRs for machinery intended for underground work harmonise standards throughout the EEA the European
6. EHSRs to offset hazards due to the lifting of moving of persons Commission charged CEN (Commission for European
reports
• If so desired a certificate or technical report obtained Step 4: CE Mark
from a competent body in support of standards Affix the CE mark to machines which are issued with a
conformity Declaration of Conformity only. CE Marking must be affixed
• A copy of the operator’s instructions and maintenance in the immediate vicinity of the name of the manufacturer or
manual Authorised Representative and applied using the same
technique.
Non-European manufacturers must appoint someone within
Europe to hold their Technical Files and this person’s name
and address must be included in the Declaration.
Step 3: Declaration
The Declaration of Conformity is a certificate, which must
accompany every machine placed on what is termed “the
market” (unless a Declaration of Incorporation is issued
instead). The manufacturer of a machine automatically
places the machine on “the market”. The Declaration is the
manufacturer’s assurance to the customer that the product
complies with the applicable directives. The Declaration
carries relevant product information and is signed by a
responsible person on behalf of the manufacturer or
importer.
TÜV SÜD Product Service • TÜV SÜD Group • Email: info@tuvps.co.uk • www.tuvps.co.uk
A practical guide to machinery safety | EMC Solutions
section five
EMC
Solutions
EMC Solutions
and a mandatory requirement from 1996, are twofold:
Electromagnetic compatibility (EMC) is an issue that many mentioned earlier – the only relaxation of the rules relates to
machine builders find complex and confusing, but that doesn’t assessment and marking, not to performance!
mean that they can ignore their legal obligation to ensure
their products meet the requirements of the EMC Directive. But how can machine builders be sure that their products
really do have satisfactory EMC performance? It’s very
There can be no doubt about the need for electromagnetic tempting to think that the answer is to use only components
compatibility (EMC). If, for example, the control system of a that are themselves compliant with the EMC Regulations.
machine is disturbed by electromagnetic interference it Surely, if all of the components used in a machine satisfy the
may randomly malfunction, creating a potentially regulations, it’s reasonable to conclude that the whole
dangerous situation. Conversely, if the electrical and machine must also meet the regulations?
electronic systems fitted to a machine generate a high level
EMC Solutions
of interference, they may cause other nearby equipment to Unfortunately, that’s not how it works and it’s relatively easy to
malfunction. It is to help guard against situations like these see why. Consider, for example, a variable speed drive that,
that the EMC Directive, 2004/108/EC, was put in place. In the for the sake of argument, produces a level of electromagnetic
UK, this directive is implemented by the Electromagnetic interference about half of that acceptable under the
Compatibility (EMC) Regulations 2006. regulations. Clearly, there’s no problem in stating that this
drive complies with the regulations.
To understand the implications of these regulations for
machine builders, a good starting point is to look at the Now put four of those drives on a machine. Is it reasonable to
“Guide to the Electromagnetic Compatibility (EMC) assume that the machine complies with the regulations, simply
Regulations 2006”. Section 2 of this guide, which covers because each of the drives is compliant? Probably not. The
essential requirements, includes statements that can be machine may be compliant, especially if measures to control
summarised as saying that equipment must be designed and EMC have been incorporated in its design, but the point is that
manufactured so that the electromagnetic disturbance it it can’t be assumed to be compliant. In fact, since there is no
creates is not excessive, and so that it has a reasonable level proven way of calculating or modelling the EMC performance
of immunity to electromagnetic disturbances. In addition, of a machine, it is the opinion of Laidler Associates that the
fixed installations – which includes the majority of machines only way compliance can be verified is by testing. This opinion
– must be installed applying good engineering practices and may be considered by some as rather controversial, but when
respecting the intended use of its components. the Health & Safety Executive was asked to comment on this
issue, it provided the following statement:
Then comes a very interesting statement, “There are no
conformity assessment or CE marking requirements for fixed “Section 6 of the Health & Safety at Work Act (HSW) places a
installations”. Does this mean that builders of machines duty on manufacturers to carry out or arrange for the carrying
categorised as fixed installations have no need to concern out of such testing and examination as may be necessary to
themselves with the EMC performance of their products? ensure that the article is so designed and constructed that it
Indeed it does not. The machines must still be designed and will, as far as is reasonably practicable, be safe and without
manufactured so that they meet the essential requirements risks to health. In the context of EMC, in most applications it is
X
Electrical
necessity for EMC testing of machines in the vast majority Mains
Filter
Cabinet
✓
Electrical
EMC Solutions
that lack in-house expertise in this specialist area. Cabinet
Unscreened cables entering and leaving the cabinet should 3. Run all control cables in separate trunking to the mains
be filtered. See diagram below. cables. If these cables must cross each other, then ensure
Unscreened cables are filtered they do so at 90 degrees to each other.
Cabinet 1 Cabinet 2
5. Use screened or armoured cables for the motor
connections and ground the screen at both ends. (See
diagrams below)
EMC Solutions
Mains
Input Cable
All metal work bonded to earth
and return cables should be twisted, i.e. Live & Neutral, 24v Control
Cable Mains cable (keep short)
and 0v. It is important not to mix signal and return cables. Note: All cables to and from the
Motor invertor/ servodrive must be
Cable screened using suitable glands. The
When bonding other parts of machinery such as doors and control cable must be kept separate
from the motor and mains cables.
lids etc. ensure that the earth straps have a large cross Terminate the screen to the
metal panel by removing the
section. Braids or thick cables are normally used for these cable sheath. (This is when
the cable glands cannot be used).
section six
PUWER
The Provision and Use of Work Equipment Regulations 1998 • After work equipment has been exposed to any
PUWER
(PUWER) requires users of work equipment to carry out risk conditions causing deterioration, which is liable to
assessment and provide work equipment that is suitable for its cause a dangerous situation.
intended task and can be used without putting persons at risk.
• At suitable intervals; and
The Regulations cover any machinery, appliance, apparatus,
tool or installation for use at work (whether exclusively or not) • Each time that exceptional circumstances have
- effectively it is anything used at work. occurred that are liable to jeopardise the safety of work
equipment. The results of these inspections have to be
The 1998 regulations (updating the original 1992 Regulations) documented and kept until the subsequent inspection is
introduce requirements to ensure that, for reasons of health recorded.
and safety, inspections are carried out:
The regulations make it an offense to allow work equipment
• After installation and before being put into service for to leave an employer’s undertaking, or if obtained from
the first time; or after assembly at a new site or in a new another undertaking, be used, unless it is accompanied by
location to ensure that it has been installed correctly physical evidence that the last inspection has been carried
and is safe to operate. out.
• The Regulations implement European Community (EC) Work Equipment that is exposed to conditions causing
Directive 89/655/EEC, amended by the non-lifting aspects deterioration liable to result in a dangerous situation must
of the Work Equipment Directive (AUWED). be inspected-
(a) At suitable intervals, and
PUWER
• The Regulations are made under the Health and Safety (b) Each time circumstances liable to jeopardise the
at Work, etc Act 1974 (HSW Act), and apply to all users safety have occurred
and the self employed covered by that Act in Great
Britain except the crews of sea-going ships. The results of any inspection made under this regulation
must be recorded. These records must be kept until the
• These regulations place a requirement to carry out a next inspection is recorded.
Risk Assessment on all existing equipment (see section Six).
Every employer shall ensure that no work equipment-
• The regulations ask that the electrical system, the (a) Leaves their undertaking, or
guarding and other possible hazards be assessed and (b) If obtained from the undertaking of another person, is
corrected if required. used in their undertaking unless
The Health And Safety At Work Act 1974 Section 2(2) It is accompanied by physical evidence that the last
Employers must, so far as is reasonably practicable: - inspection required by this regulation has been carried out.
Provide & maintain plant and systems of work that are safe • You should ensure that the persons who determine the
& without risk to health. nature of the inspections required and who carry out the
inspections are competent to do so.
Risk Assessments are a key part to any PUWER assessment and
are cross-referenced with the appropriate section/question at • The competent person should have the necessary
all times. If a non-compliance does occur and you are asked for knowledge and experience to decide what the inspection
your reports you will probably be asked primarily for the risk should include, how and when it should be carried out.
assessments carried out against the equipment in question. In
order to fully comply, Risk Assessments are carried out and • Every employer must ensure that any work equipment
where problems are found they are reported against a complies with any European Directive that applies to it.
particular section/question.
PUWER
• Can the guarding be bypassed or disabled • Are those isolators lockable
TÜV SÜD Product Service • TÜV SÜD Group • Email: info@tuvps.co.uk • www.tuvps.co.uk
A practical guide to machinery safety | Pre-Purchase Audit
section seven
Pre-Purchase
Audit
Pre-Purchase Audit
clients to purchase machinery and equipment that is both
safe and correct.
PUWER
The Solution
What to look at
Background will highlight any safety issues, which may have an effect
When the Provision and Use of Work Equipment Regulations on the CE Marking of the equipment. Any issues that appear
(PUWER) first came into force in 1992 it included a very to relate to the CE Marking of the equipment should be
simplistic view on CE Marking: the end user only has to raised with the manufacturer or supplier of the equipment.
check that the equipment concerned carried a CE Mark. If it However, as the equipment has been installed it may be
did, they were able to presume conformity. PUWER was more difficult to deal with.
updated in 1998 and one of the more important, but easily
overlooked, changes was that the onus was now put on the The Solution
end-user to make sure that the equipment complies with all A solution to this is to use a User Requirement Specification
relevant legislation such as CE Marking. These changes (URS) when purchasing new equipment. This specification
were re-enforced with further changes in June 2002. will outline your requirements for the equipment supplier. A
Pre-Purchase Audit
PUWER To ensure compliance with the URS, the equipment may need
To fully comply with PUWER, any new equipment should be to be inspected or audited before it is shipped from the
inspected after installation and before it is put into use to manufacturer or supplier. But this inspection need not be
make sure it is safe. This inspection, if carried out correctly, limited to only safety issues. Often a purchaser may want to
Pre-Purchase Audit
process once the equipment has been shipped. Retrofitting • Maintenance and cleaning procedures
is the more difficult method of compliance; it is always • Training requirements
advisable to deal with safety as early as possible in the
purchasing process, the design stage being preferable. It may also be beneficial at this stage to collate all the
relevant documentation such as manuals, drawings etc so
So, if as a company, you decide to include such an audit in your that a file is in place when the equipment arrives on site.
equipment purchasing policy, what would you need to look at
and who should carry out the audit? Dealing with the person External Assistance
first, they should have a good knowledge of the equipment type There may be many reasons why a company feels that a pre-
itself as well as competent understanding of PUWER and CE purchasing audit is not feasible. It may be manpower, time,
Marking legislation and have a sound engineering background competence or a mixture of the three. Laidler Associates
to understand the latest developments in machine manufacture. currently carry out this kind of audit for a number of major blue
Whilst the auditor may not go through the EHSRs as in-depth as chip companies, both in the UK and abroad. Following the audit,
the manufacturer, the same areas need to be covered. It may be the client will receive a full report highlighting any problem areas
beneficial for the auditors to create a generic checklist that can with a recommended corrective action. Laidler can also carry out
be used so that all people who are carrying out an audit for the an inspection to enable compliance with PUWER and Project
company are looking at the same points. Manage any retro engineering that needs to be carried out.
Areas to look at include: Laidler Associates also have experience of writing URS’ for
• Documentation, manuals etc. clients from amongst others, pharmaceutical and automotive
• Drawings, electrical pneumatic, hydraulic etc. companies. Laidler can also tailor the Risk Management
• Electrical wiring and termination checks Software system, to include the URS.
Hands-on engineering
solutions for machinery
compliance
:: Engineering Services :: Bespoke Guarding
:: ESPE Assessments :: Design, installation &
project management
Safety Systems
Technology
section eight
Engineering
Services
Engineering Services
Product Service Ltd, and provides engineering services to ensure
machinery compliance, including full engineering project
management of compliance solutions bespoke guarding and Electrical Engineering
safety product sales. As market leaders in machinery safety
compliance engineering, we have the knowledge and experience
to design and install the most appropriate safety solutions using
Machine Guarding
products from our wide ranging portfolio from leading
manufacturers. Services include: Safety Product Sales
• Project Definition and Design Studies
• Multidiscipline Project Management
• System Specification and Design
• Electrical Design and Build including control circuits
• Guarding Design
• Commissioning and Installation
• Ongoing Support and Training
• Modifications to ensure legal compliance
• ESPE (light curtain) assessments
• Safety Product Sales
requirements:
Documentation
• Physical guarding designed and built to EN 953 & EN ISO 13857 The following documentation can be generated by SST
• Safety control circuitry designed to EN 954-1, EN ISO 13849 during the project, "As Commissioned" copies of which will
or EN 62061, depending on the system that is required be supplied to yourselves following the completion of the
• The selection of the most suitable safety products (interlocks, project in either/both hard copy and/or electronic format.
light curtains etc) as appropriate for the project in question
• Functional Design Specification (FDS)
Appropriate EN Standards will be used throughout this design • Relevant Diagrams
stage to ensure compliance with all relevant items of legislation. • Factory Acceptance Test
Finals designs will be signed off by the end user before • Documentation
work begins on the production of the remedial items. • Manuals relating to SST installed equipment
• Technical Construction File
Factory Acceptance Test (FAT) • EMC and Low Voltage test results
On completion of the works, it will be possible to carryout
Factory Acceptance Testing (FAT) which will enable the system In line with SST quality procedures and in the interest of a
to be tested against the requirements set out in the FDS. successful project SST require approval of the design
definition documents before proceeding with detail design,
Installation and Sign off build, installation, and commissioning. In respect of the
All work will be carried out in accordance with BS 7671 (IEE purpose of the project it may be beneficial for reviews and
17th Edition Regulations) and EN60204-1 as appropriate. approvals of the control system design to be carried out
SST requires full access to all in order to carry out the jointly between yourselves and Laidler Associates.
installation of both the guarding and control system during Approval provider can be discussed and confirmed
the installation period of the project. following order placement.
Engineering Services
Machine Guarding be supplied to yourselves following the completion of the
Machinery Directive 2006/42/EC, which was introduced on project in either/both hard copy and/or electronic format.
December 31st 2009, fundamentally changed the
requirements for machinery guarding. Annex V of the
Directive is an indicative list of safety components and
includes indent 7: “Guards and protective devices designed
to protect persons against moving parts involved in the
process on the machinery”, hence guarding must now carry
CE Marking and be issued with a Declaration of Conformity.
Perimeter Guarding
Safety Systems offer flexible perimeter guarding solutions
as both off the shelf or bespoke solutions for particular
applications.
This flexibility makes modification of the design easy at any • Durable powder coated mild steel, stainless steel or
stage of the process, ensuring that all guarding meets client anodised aluminium construction
expectations, operator requirements and the relevant EN • A range of heights from 1.4m to 3.0m
standards. • A range of duty ratings for different environments and
impact resistance
Localised Guarding • Access options such as hinged or sliding single or
Safety Systems can offer a wide range of localised double doors, trackless doors and vertical gates
guarding solutions for any industrial application, including: • A variety of infill materials such as sheet steel, weld-
• Process mesh, clear or tinted polycarbonate
• Pharmaceutical • Locking options such as snap locks, cylinder locks and
• Food and drink panic locks
• Packaging • Simple assembly and installation
• Automotive • A wide range of colours
• Paper & board
Typical Products
Safety Systems are not tied to any safety product
manufacturers and hence can supply the most relevant
Engineering Services
product for a customer’s needs. Products that are supplied
regularly include:
• Safety Switches
• Safety Relays
• Interlocks
Permanent Means of Access to Machinery • Light Curtains
In addition to machinery guarding, Safety Systems can also
advise upon, design and supply permanent means of access
to machinery in accordance with BS EN ISO 14122 Parts 1-4. Products can be supplied from manufacturers such as:
Safety Systems
Technology
section nine
Appendices
Appendices
that can be used to make-up a machinery safety inspection.
Please feel free to photocopy before using.
Risk Assessment
Please note the use of the checklists does not guarantee
compliance, they should be used as aide memoires as part Technical File index
of an inspection.
Nature of Hazard
Risk Assessment
LO FE DPH NP HRN
Degree of Risk
Re-Assessment
LO FE DPH NP HRN
Degree of Risk
Position: .................................................................
Date: .......................................................................
RISK Negligible Very Low Low Significant High Very High Extreme Unacceptable
HRN 0-1 1-5 5-10 10-50 50-100 100-500 500-1000 Over 1000
Review Dates
1B Risk Assessment
2D Electrical Checklist
2E Pneumatic Checklist
2F Hydraulic Checklist
5C Specific Drawings
6B Maintenance Manual
6C Other Manuals
Safety Systems
Technology
SAFETY SYSTEMS TECHNOLOGY
TÜV SÜD Group
Unit 3, Westbury Street
Elland, Halifax
HX5 9AT United Kingdom
Telephone: +44 (0)8450 750008
sales@safetysys.co.uk www.safetysys.co.uk