Introduction
Objectives of Safety Engineering Safety necessitates protection against risks posed to Persons Machines Processes Environment Risks arising from malfunctions have to be prevented before they even occur. 08/2008 Slide 3/48 Siemens AG 2008 -Subject to modifications
Market and Motivation Protection of persons Social responsibility in Europe and North America Directives necessitate innovations for reducing cost pressure and maintaining productivity Globalization: Considerable productivity increases necessary due to global competition Further productivity increases coupled with social responsibility are only possible with innovative safety engineering concepts! 08/2008 Slide 4/48 Siemens AG 2008 -Subject to modifications
Consistent Realization of Safety-Related Applications with Production industry Conveyor technology Presses Processing machines Machine tools... Process industry Burner controls Oil industry Chemical industry... Passenger transportation Cableways Lifting platforms... No matter whether your safety requirements are simple or highly complex we are your worldwide competent and reliable contact partner for sector-specific safety concepts. 08/2008 Slide 5/48 Siemens AG 2008 -Subject to modifications
Applications & sector examples Conveyor technology Flughafen Airports Transport Fairground Automotive Machine tools Printing machines Food & Beverage 08/2008 Slide 6/48 Siemens AG 2008 -Subject to modifications
Safety Necessitates Protection Against all Risks Safety implies protection against... Electric shock Heat and fire Hazardous radiation Risks posed by malfunctions Functional safety is one aspect of overall safety, which depends on the correct functioningof the safety-related (control) system. 08/2008 Slide 7/48
Functional Safety Serves the Protection of... Persons and Machines...andthus represents an essential componentof all automation concepts. 08/2008 Slide 8/48
Risks in Technical Installations Risk analysis Risk reduction Risk potential for persons, processes and machines What? Against what? Why? Adjustment of the the machine concept Further measures for risk reduction Safety systems Through what? Acceptable risk "Zero risk" cannot be realized. 08/2008 Slide 9/48
Safety Performance Scale The required safety-related efficiency (safety performance) is scaled according to risks. The risk potential is scaled on the basis of SIL and categories. SIL (Safety Integrity Level) / PL (Performance Level) Solution-independent Clear scaling according to the risk potential Performance level (PL) Average probability of a dangerous failure per hour [1/h] SIL [EN 61508-1 (IEC 61508-1)] for information a 10-5 to < 10-4 No special safety requirements b 3 x 10-6 to < 10-5 1 c 10-6 to < 3 x 10-6 1 d 10-7 to < 10-6 2 e 10-8 to < 10-7 3 SILand PL can be mutually derived from each other. 08/2008 Slide 10/48
International Safety Standards USA: UL, ANSI Europe: IEC, EN Japan: JIS The regulations and standards applicable at the installation location of the system or machine are decisive. All countries follow the same basic principles for application.the European standards and regulationsare recognizedworldwide. 08/2008 Slide 11/48
Standards and Certificates All safety-related components meet high safety standards: IEC 61508 (up to SIL 3) EN 954 (up to Category 4) NFPA 79-2002 NFPA 85 and are correspondingly certified. 08/2008 Slide 12/48
The Systematic Safety Solution: The Portfolio From sensors, to evaluation units, down to drives with integrated safety functions the portfolio offers maximum,consistent safety. 08/2008 Slide 13/48
Integrated Safety Technology Overview of the Factory and Process Safety Portfolio Production automation Process industry Conveyor technology Presses Production machines Machine tools... Burner controls Oil industry Chemical industry... PLCs Relays Factory safety Sensors Drives Process safety SIS Failsafe PLCs Failsafe I/Os Failsafe relays Configurable failsafe relays Light curtains Light grids Laser scanners Safety mats Position switches EMERGENCY-STOP Failsafe drives Motion control Safety controllers Redundancy Failsafe I/Os Bus systems Pressure transmitters 08/2008 Slide 14/48
SIMATIC FS400 Light Curtains, Light Grids and Transceivers Product features: Particularly interference-proof and highly available through specially developed integrated circuits (ASICs) and intelligent evaluation principle Various resolutions Extended functionality options: blanking, muting, clock control Applicable for various safety categories: Cat. 2 or Cat. 4 in accordance with EN 954-1 or Type 2 and 4 in accordance with IEC/EN 61496-1 Typical application areas: Finger and hand protection in hazardous locations Horizontal and vertical danger zone protection Light grids for access protection 08/2008 Slide 15/48
SIMATIC FS600 Laser Scanners Product features: Vertical or horizontal protection possible Operating range of 190 EN 954-1, Cat. 3 Distance of up to 4 m Definition of various protective fields Supports PROFIBUS with PROFIsafe and AS-Interface with ASIsafe Typical application areas: Horizontal danger zone protection with one or several protective fields Access protection through passage control Track monitoring for automated guided vehicle systems Collision protection for transfer carriages Risk protection through hand and arm protection 08/2008 Slide 16/48 Horizontal danger zone protection with several protective fields
Failsafe Industrial Controls: SIRIUS Individual safety for highest demands Detecting Commanding & signaling Monitoring & evaluating Starting & safe disconnecting ASIsafe: Fast commissioning and easy parameterization DP/AS-i F--Link ASIsafe module SIRIUS contactor SIMATIC light curtain SIRIUS 3SB 2/3 position switch 3SB3 8WD signaling EMERGENCY-STOPcolumn ASIsafe enhanced safety monitor Motor 1 08/2008 Slide 17/48
Failsafe Industrial Controls: SIRIUS Position switches Position switches Hinge switches Short-stroke switches 3SE6 magnetically operated switches ASIsafe modules For high safety requirements Commanding devices 3SB3 EMERGENCY-STOP switches 3SE7 cable-operated switches 3SB8 two-hand operation consoles 3SE2 foot switches 8WD4 signaling columns 8WD5 integrated signal lamps Safety relays Modular safety system Electronic enabling circuits Relay contact enabling circuits Contactor relay enabling circuits 3TK2845 multifunction devices Efficient solutions for safety applications 08/2008 Slide 18/48 Modular design Evaluation of several safety functions Great linkage depth Parameterization / diagnostics via software Data exchange via PROFIBUS Flexible solution for safety applications with several sensors and actuators
3RK3 Basic Modular Safety System Application Example Diagnostics PLC MSS Basic MSS ES software Sensor 1 Sensor 2 Sensor x Control cabinet Easy assignment of sensors to the enabling circuits via MSS ES Diagnostics is realized via PROFIBUS to the PLC 08/2008 Slide 19/48 Siemens AG 2008 -Subject to modifications
Failsafe Industrial Controls: SIRIUS Motor Starters for SIMATIC ET 200pro Performance range: Up to 7.5 kw for direct and reversing start-up Degree of protection: IP65 Selective detection of safety signals Selective, safe disconnection of motor feeders Safety Motorstarter Solution local: Up to Cat. 4 with F-RSM repair switch module and ASM disconnecting module Safety Motorstarter Solution PROFIsafe: Up to Cat. 2 with F-Switch and electro-mechanical motor starter Up to Cat. 3 or 4 with F-Switch, ASM disconnecting module, electro-mechanical / electronic motor starter Safety Motorstarter Solution local: For locally limited safety applications Safety Motorstarter Solution PROFIsafe: Demanding and networked safety solutions with failsafe control 08/2008 Slide 20/48 Siemens AG 2008 -Subject to modifications
Failsafe Industrial Controls: SIRIUS Motor Starters for SIMATIC ET 200S Performance range: Up to 7.5 kw for direct and reversing start-up Selective detection of safety signals Selective, safe disconnection of motor feeders Safety Motorstarter Solution local: Up to Cat. 4 in acc. with EN 954-1, SIL 3 in acc. with IEC 61508 Integration in existing safety concepts Suitable for EMERGENCY-STOP and protective door monitoring Stop categories 0 and 1 (controlled shutdown with integrated delay) Safety Motorstarter Solution PROFIsafe: Up to Cat. 4 in acc. with EN 954-1, SIL 3 in acc. with IEC 61508 Failsafe communication via PROFIBUS/PROFINET with PROFIsafe profile Effective diagnostics functions and fast device replacement possible during ongoing operation Safety Motorstarter Solution local: For locally limited safety applications Safety Motorstarter Solution PROFIsafe: Demanding and networked safety solutions with failsafe control 08/2008 Slide 21/48 Siemens AG 2008 -Subject to modifications
AS-Interface with ASIsafe The Concept Safety-relevant and standard data via a single bus ASIsafe Solution local via safety monitor ASIsafe Solution PROFIsafe via DP/AS-i F-Link asimon V3 parameterization and diagnostics software Easy connection of safety-oriented components such as EMERGENCY-STOP or safe sensors to AS-Interface Safe disconnection up to Category 4 in accordance with EN954-1 / SIL 3 in accordance with IEC 61508 08/2008 Slide 22/48
ASIsafe Solution local: Safe and Standard Components Via a Single AS-i Line! Components of the ASIsafe solution local 08/2008 Slide 23/48
ASIsafe Solution PROFIsafe: Safe and Standard Components Via a Single AS-i Cable! Components of the ASIsafe solution PROFIsafe 08/2008 Slide 24/48
The ASIsafe Portfolio Safety monitor Monitoring of safe stations and networking of safe inputs Fast configuration Easily configurable safety functions up to Category 4 Safe modules Degree of protection IP65/IP67 or IP20 2 or 4 inputs in Cat. 2* or 1 or 2 inputs in Cat. 4 / SIL3* 4 safe inputs or 2 additional standard outputs Easy integration of safe signals in the control cabinet or field Safety sensors Position switches Cable-operated switches EMERGENCY-STOP Laser scanners up to Cat. 3 Light curtains up to Cat. 4 Easy connection to AS-i F-Link to PROFIBUS DP In a single device: AS-i master (Spec. 3.0) and safety monitor Transfer of safe input signals to PROFIsafe architectures Configuration via STEP 7 Distributed Safety Compact gateway for optimum transfer from ASIsafe to PROFIsafe 08/2008 Slide 25/48
SIMATIC : For All Requirements Safe & highly available Application focus: Process automation Controllers CPU 412H CPU 414H CPU 417H Engineering CFC Safety matrix Failsafe Application focus: Factory automation Controllers for PROFIBUS ET 200S F-CPU CPU 315F/317F/319F CPU 416F for PROFINET CPU 315/317F/319F CPU 416F Engineering FBD, LAD PROFIBUS with PROFIsafe profile Actuators Sensors PROFINET with PROFIsafe profile ET 200M ET 200ecoET 200S ET 200pro ET 200S ET 200pro 08/2008 Slide 26/48
Innovations From the Proprietary Solution to the Failsafe PLC Before: Standard and safety automation separated in two systems New: Standard and safety automation integrated in one system Failsafe I/O Standard PLC EMER- GENCY- STOP Standard I/O Failsafe I/O EMERGENCY- STOP Failsafe PLC Failsafe SIMATIC EMERGENCY- STOP Standard & failsafe I/Os EMERGENCY- STOP Failsafe I/O EMERGENCY- STOP EMERGENCY- STOP PROFIBUS PROFINET or PROFIBUS with PROFIsafe profile Safety bus 08/2008 Slide 27/48
Failsafe Communication via PROFIsafe for PROFIBUS & PROFINET Safety-related communication via PROFIsafe profile First communication standard in accordance with the IEC 61508 safety standard. The PROFIsafe profile supports safe communication for the PROFIBUS and PROFINET open standard buses. The PROFIsafe profile prevents potential faults such as incorrect addressing, delays and data loss through Consecutive numbering of the PROFIsafe data Time monitoring Authenticity monitoring by means of unique addressing Additional CRC protection Safetyoriented data PROFIBUS DPStandard PROFINET IOBUS protocol PROFIBUS or PROFINET PROFIsafe layer Standard data Safetyoriented data PROFIsafe layer Standard BUS protocol Standard data Black channel" PROFIsafe supports standard and failsafe communication via one physical bus 08/2008 Slide 28/48
Drive Technology with Integrated Safety Functions Overview Drive technology segments Simple applications Electric drive technology Standard applications Motion control applications Application areas Conveyor technology, pumps, fixed-speed units Conveyor technology, pumps, variable-speed units Motion control, positioning, track control Mode of operation ON/OFF operation or fixedspeed continuous operation ON/OFF operation, variablespeed continuous operation Continuous operation with high speed accuracy or cyclic operation with frequent acceleration / deceleration Acceleration/ Dynamics Low Average High to very high Open-/closed-loop control ON/OFF V/f control, vector control Vector control, servo control Products IP20 IP65 Motor starters Frequency converters Servo / vector drive systems 08/2008 Slide 29/48
Failsafe Drives SIMATIC ET 200S FC Frequency Converters for Distributed I/Os Performance range: 0.75 kw 4 kw Safety functions: Safe torque off (STO) Safe stop 1 (SS1) without motor encoder Safely limited speed (SLS) Certified in accordance with IEC61508, SIL 2 and EN 954-1, Cat. 3 High efficiency through autonomous, certified safety functions Short response times through integration in the ET 200S system The module versatility of the ET 200S range offers high flexibility for safetyoriented drive solutions 08/2008 Slide 30/48
Failsafe Drives SIMATIC ET 200pro Frequency Converters Distributed, Safe and Energy-Saving Performance range: 1.1 kw at 55 C (1.5 kw at 45 C) Degree of protection: IP65 Safety functions: Safe torque off (STO) Safe stop 1 (SS1) Safely limited speed (SLS) Certified in accordance with IEC 61508, SIL 2 and EN 954-1, Cat. 3 in the drive for efficient safety applications Fast module replacement and consistent diagnostics options through integration of the frequency converters in Simatic ET200pro For high-quality conveyor technology applications, e.g. in the automobile industry Innovative energy recovery generates manifold cost advantages Communication via PROFIBUS Simple, central, plant-wide engineering 08/2008 Slide 31/48
Failsafe Drives SINAMICS G120 Frequency Converters Modular, Safe and Energy-Saving Performance range: 0.37 kw 90 kw Safety functions: Safe torque off (STO) Safely limited speed (SLS) Safe stop 1 (SS1) Safe brake control (SBC) Certified in accordance with EN 954-1, Cat. 3 and IEC 61508, SIL 2 in the drive for efficient safety applications Fast module replacement and consistent diagnostics options through integration of the frequency converters in Simatic ET200pro For high-quality conveyor technology applications, e.g. in the automobile industry Innovative energy recovery generates manifold cost advantages Communication via PROFIBUS Simple, central, plant-wide engineering 08/2008 Slide 32/48
Failsafe Drives SINAMICS G120D Frequency Converters Distributed, Safe and Energy-Saving Performance range: 0.75 kw 7.5 kw Degree of protection: IP65 Safety functions: Safe torque off (STO) Safe stop 1 (SS1) Safely limited speed (SLS) Certified in accordance with IEC 61508, SIL 2 and EN 954-1, Cat. 3 in the drive for efficient safety applications For high-quality conveyor technology applications, e.g. in the automobile industry Optimized mechanics: Very flat design and uniform drilling pattern in all performance ranges Innovative energy recovery generates manifold cost advantages High mechanical and electrical ruggedness Communication via PROFIBUS Simple, central, plant-wide engineering 08/2008 Slide 33/48
Failsafe Drives SINAMICS S120 The Flexible Drive System for Demanding Drive Tasks Performance range: 0.12 kw 4,500 kw Safety functions: Safe torque off (STO) Safe operating stop (SOS) Safe shutdown (SS1, SS2) Safe brake control (SBC) Safely limited speed (SLS) Safe speed monitoring (SSM) PROFIsafe Certified in accordance with IEC 61508, SIL 2 and EN 954-1, Cat. 3 Ideally suited for high-performance drive tasks: Positioning, motion control, track control For single and multiple-axis applications With servo and vector control For synchronous and asynchronous motors Automatic configuration and flexible combination options with DRIVE-CLiQ system interface 08/2008 Slide 34/48
SINUMERIK Certified Safety Functions for Processing Machines Safety functions: Safe torque off (STO) Safe shutdown (SS1, SS2) Safe operating stop (SOS) Safely limited speed (SLS) Safety software cams Safety software limit switches Safety-oriented inputs/outputs Safe programmable logics Safe brake control (SBC) Safe brake test Safe system coupling Safe communication via Profibus DP (PROFIsafe profile) Safe gateway from ASISafe to PROFIsafe Numerical control with integrated, flexible safety functions for efficient and innovative protection concepts 08/2008 Slide 35/48
Always the Suitable Solution with Requirements: Evaluation unit / communication: Integrated solutions for machines with high requirements Flexible solutions for multifunctional machines Solutions for machines with distributed sensors Control-based, highly flexible concept with Profibus / Profinet with PROFIsafe Modular safety system for the connection of several sensors and actuators AS-Interface with ASIsafe as local or integrated solution Flexibility Simple solutions for compact machines Local concept with safety relays 08/2008 Slide 36/48
Solutions with Control-based, highly flexible concept with Profibus / Profinet with PROFIsafe Modular safety system for the connection of several sensors and actuators AS-Interface with ASIsafe as local or integrated solution Local concept with safety relays 08/2008 Slide 37/48
Trends (1) Solutions for the various requirements of all industries worldwide necessitate innovative approaches. From the individual solution to the integrated overall solution: Not only for the safety level, but also for the standard components of a system with their programming and configuration tools. This requirement is fully met by, representing a decisive step towards the future. The consistent implementation of distribution, also of safety-relevant signals, results in substantial cost savings. Safe automation combined with safe drive technology. 08/2008 Slide 38/48
Trends (2) The increasing application of electronics and computer technology in the field of safety engineering facilitates new, more complex functions, such as: State-independent interlocking Speed limiting Position limiting Controlled shutdown Controlled stop and supports the realization of resulting new safety concepts. 08/2008 Slide 39/48
Customer Benefits at a Glance (1) One partner Consulting, products, systems, solutions and services from a single source High efficiency Safety engineering, standard automation and drive technology integrated in one overall system. Minimized costs through reduced hardware requirements and faster installation and commissioning. More efficient engineering through the application of standard software also for safety engineering. High availability of machines and systems with the same or greater safety level. Effective and rapid diagnostics functions for maximum availability of machines and systems. Easy realization of safety-related, integrated communication via standard field buses. 08/2008 Slide 40/48
Customer Benefits at a Glance (2) Ease of handling Fast realization of the safety-relevant functions. High acceptance by the operating personnel. Compliance with standards All products meet the relevant standards and support the standard-compliant assembly of machines and systems. Early adjustment of products to standard changes through active involvement in the relevant committees. Intelligent safety engineering Facilitates user-friendly machines which can be integrated in the work flow. 08/2008 Slide 41/48
Reference: Control-Based Safety Concept Control-based drive concept at Michelin Kronprinz Task: Upgrading of a rim profiling line to Safety Category 4 in accordance with EN 954-1 for maximum flexibility Solution: Safety concept based on SIMATIC S7-315F assembled in parallel with the existing line control. Control of failsafe signals via ET 200S. Advantages Comprehensive diagnostics options for maximum flexibility Time savings thanks to visualization of all states during commissioning Compensation of the slightly higher investment costs through performance gain as of two protective circuits 08/2008 Slide 42/48
Reference: Flexible Safety Concept for Cutting Systems Flexible safety concept for cutting systems at Frimo-Heidel Viersen Task: Realization of an adjustable safety concept for Duojet water jet cutting system Solution: ASIsafe concept for optimized response times and space requirements. A SIMATIC S7-314 2DP controls the cell with the water jet cutting robots and the turntable. The control is connected to a DP/AS-i-Link, which monitors all slaves (standard / failsafe) as AS-i master, via PROFIBUS. Advantages Easy installation and engineering Short response times Comprehensive diagnostics options Flexible and easy modular expandability 08/2008 Slide 43/48
Reference: 3-in-1 Concept for Planing and Molding Machines 3-in-1 concept for planing and molding machines at Kuper Task: Realization of an individual safety concept for new planing and molding machines Solution: Simple but effective safety concept with the SIRIUS 3TK28 multifunction device. The safety relay protects the planing and molding machines in various manners as it combines three functions in one device: EMERGENCY-STOP, hood monitoring and setting operation via key switch. Advantages Considerably reduced wiring expenditures Simple and efficient construction Key switch function for switchover between setting and normal operation 08/2008 Slide 44/48
Service and Support Contact partners: Global sales network and qualified promoters on site 24-hour hotline Services: Risk analysis & assessment consulting Product and application consulting Project coaching Online support with documentations, applications, tools, FAQ, software updates, online support request http://support.automation.siemens.com Trainings Product and application training Trainings on standards www.siemens.com/sitrain-safetyintegrated 08/2008 Slide 45/48
System Partners Seamless Service Portfolio Selected qualified partners all around the world support you with mastering the growing requirements in the field of safety engineering. Based on their sector competence and longstanding experience, our trained and certified partners offer consulting and support services for your automation projects safety aspects. Safety check Check of the safety functions of systems and machines. Safety consulting Assessment of machine safety in accordance with applicable standards. Safety engineering Complete realization from planning down to commissioning. www.siemens.com/safety-partner 08/2008 Slide 46/48
Information Material on brochure E20001-A150-M103-V5-7600 Functional Safety of Machines and Systems brochure E20001-A230-M103-V1-7600 Collection information DVD E20001-Y310-M103-X-7400 Functional examples http://support.automation.siemens.com Catalog: E86060-K1005-B101-A2-7600 Terms & Standards E86060-T1813-A101-A1 Internet www.siemens.com/safety 08/2008 Slide 47/48
Safety Thank you Integrated www.siemens.com/safety-integrated