Machinery Safety - Validation

• AS 4024-1502:2019 Validation of Machinery

• Document No.

• Client / Site

• Conducted on

  Date

• Prepared by

Objective and Scope

Validation

Standards Referenced in this document

• Revision Number

• Revision Reason

• By whom

Details:

• undefined

Documentation Reviewed

• Risk Assessment reviewed

  Select

• Are there Functional Safety Descriptions (FSDs) available?

  Select

• Check with OEM for pre start checklists of safety functions. They should be reasonably expected to share this along with the Functional Safety Descriptions

• Is an SRS (Safety Requirements Specifications) available?

  Select

• Is there a SISTEMA report or similar?

  Select

• Is there any FAT or pre-start commissioning checklists available?

  Yes

  No

  N/A

  Actions Required

• Document Number:

• Is the Performance Level of the machinery determined by OEM or Risk Assessment

  Yes

  No

  N/A

  Actions Required

• What is the required PLr for the machinery? [From risk assessment or site minimum requirement.]

  Select

• Are all tasks and hazards associated identified in the risk assessment

  Select Yes No Yes but combined with other safeguards such as ESPE Integration to other machinery may give rise to further analysis

  • Yes
  • No
  • Yes but combined with other safeguards such as ESPE
  • Integration to other machinery may give rise to further analysis

Machine Identification

• Type of Machinery

  Select Packaging Processing Conveyors ASRS Distribution Manual Handling or Ergonomic Handling Potato Recieval Services WWTP Bag Makers Milling Forklifts or PTO Agronomy Bin Lifters Automatic Case Packers Robotic Palletisers Potato Peelers Potato Washers Potato Receival Sealing and Taping Machinery Carton Erectors Slicers Auto Halvers Optical Sorters Seasoning Flavour Application Automatic Feeder Print Unit Distribution Palletiser Stacker Strapper Roller conveyor Die-cutter Dryer Waste Auger Stretch Wrapper Pallet Loader Pallet Inserter Pallet Stacker Tote Washer Decant Station Picking Station Shrink Wrapper Fruit / Vegetable Slicer Bakery - Mixer Bakery - Dough Preparation Bag Sealer Bakery - Dough Prover Bakery - Oven Truck / Vehicle Washer Inspection System (totes / boxes) Automatic Carton Erector Conveyor Cross overs Robotic Element Mining - CNV Drive End Mining - CNV Head End Mining - CNV Mid Point Scissor Lift - Spring type Scissor Lift - Automated EWP Rail Mounted Crane (Mini-load) MIR - small (> 1200mm x 1200mm) Rail Mounted High Bay Crane

  • Packaging
  • Processing
  • Conveyors
  • ASRS
  • Distribution
  • Manual Handling or Ergonomic Handling
  • Potato Recieval
  • Services
  • WWTP
  • Bag Makers
  • Milling
  • Forklifts or PTO
  • Agronomy
  • Bin Lifters
  • Automatic Case Packers
  • Robotic Palletisers
  • Potato Peelers
  • Potato Washers
  • Potato Receival
  • Sealing and Taping Machinery
  • Carton Erectors
  • Slicers
  • Auto Halvers
  • Optical Sorters
  • Seasoning
  • Flavour Application
  • Automatic Feeder
  • Print Unit
  • Distribution
  • Palletiser
  • Stacker
  • Strapper
  • Roller conveyor
  • Die-cutter
  • Dryer
  • Waste Auger
  • Stretch Wrapper
  • Pallet Loader
  • Pallet Inserter
  • Pallet Stacker
  • Tote Washer
  • Decant Station
  • Picking Station
  • Shrink Wrapper
  • Fruit / Vegetable Slicer
  • Bakery - Mixer
  • Bakery - Dough Preparation
  • Bag Sealer
  • Bakery - Dough Prover
  • Bakery - Oven
  • Truck / Vehicle Washer
  • Inspection System (totes / boxes)
  • Automatic Carton Erector
  • Conveyor Cross overs
  • Robotic Element
  • Mining - CNV Drive End
  • Mining - CNV Head End
  • Mining - CNV Mid Point
  • Scissor Lift - Spring type
  • Scissor Lift - Automated
  • EWP
  • Rail Mounted Crane (Mini-load)
  • MIR - small (> 1200mm x 1200mm)
  • Rail Mounted High Bay Crane

• Basic machine operation

• Photo

  Media

• Installation type

  Select

• Manufacturer of Machine

• Machine Model Number

• Machine Serial Number

Documentation Reviewed

• Document Type

  Select

• Document Number

Machinery Safeguarding Analysis

• Area of machine:

  Select

• Safeguards are required on this machine.

  Yes

  No

  N/A

  Actions Required

• Type of Safeguards

  Select

• Safeguards selected are the appropriate type for the process

  Yes

  No

  N/A

  Actions Required

• Detail Recommended Actions

• Safeguards are fixed in place and secured by appropriate fixings and correctly interlocked?

  Yes

  No

  N/A

  Actions Required

• Detail Recommended Actions

• All identified gaps are considered compliant

  Yes

  No

  N/A

  Actions Required

• Detail Recommended Actions

• Safeguards prevent access to dangerous moving parts?

  Yes

  No

  N/A

  Actions Required

• Detail Recommended Actions

• A tool is required to remove existing guarding.

  Yes

  No

  N/A

  Actions Required

• Guarding is Compliant when (According to ISO14119) guard fixings are considered tamperproof and robust enough to withstand tampering.

• Is there a permit system in place prior to the removal of guarding. (Safe System of Work)

  Yes

  No

  N/A

  Actions Required

• Supervision of all tools required to open guards is strongly recommended. Operators and cleaners for example should not have uncontrolled access. FLM or local supervisor should retain and log usage of such tools for verification (incident management). It is normal for maintenance to have access to such tools.

• Are all electrical fixtures are covered and locked.

  Yes

  No

  N/A

  Actions Required

• Detail Recommended Actions

• All electrical cabinets, MCC's DB's and control boxes must be securely fitted with covers and locked at all times such that only certified electrical personnel have access. Per AS/NZS 3000:2008

• Machinery has integrated safeguarding (eg two-handed or hold-to-run jog operation) allowing operation through guards [not whole of body access]

  Yes

  No

  N/A

  Actions Required

• See details in Predictable Failure Testing

• Walkways, platforms, self-closing gates and guard rails are used to allow safe access to machinery?

  Yes

  No

  N/A

  Actions Required

• Are they compliant?

  Yes

  No

  N/A

  Actions Required

• Detail Recommended Actions

• Monitoring, adjustment or maintenance points are located outside the guarded area to allow safe maintenance.

  Yes

  No

  N/A

  Actions Required

• Is LOTO isolation present on the machinery and appropriately located outside of the guarded or hazardous areas?

  Yes

  No

  N/A

  Actions Required

• Electrical Isolator is fitted

  Yes

  No

  N/A

  Actions Required

• Pneumatic Isolator is fitted

  Yes

  No

  N/A

  Actions Required

• Hydraulic Isolator is fitted

  Yes

  No

  N/A

  Actions Required

• Steam Isolator is fitted

  Yes

  No

  N/A

  Actions Required

Phase 2 Validation of the Logic System

• What SRPCS Safety logic system is used?

  Select Safety Relays Safety Configurable Relays Safety PLC No Safety Logic Required Combination of Safety Logic and Safety Relays Safety Logic required but not installed

  • Safety Relays
  • Safety Configurable Relays
  • Safety PLC
  • No Safety Logic Required
  • Combination of Safety Logic and Safety Relays
  • Safety Logic required but not installed

• Is there an SSRS available or evidence of safety software fault testing?

  Yes

  No

  N/A

  Actions Required

• Enter into documents reviewed list if not already done.

  Select Test Concurrent or Sequential Muting Test Override is not permanent Test Muting Lamp Feedback (where fitted) Light Curtains Revert to normal operation post mute

  • Test Concurrent or Sequential Muting
  • Test Override is not permanent
  • Test Muting Lamp Feedback (where fitted)
  • Light Curtains Revert to normal operation post mute

• How has the software been checked for errors and systematic failures?

• All the safety logic devices securely mounted (DIN rail or screw base etc)

  Yes

  No

  N/A

  Actions Required

• All the connections to the safety devices secure?

  Yes

  No

  N/A

  Actions Required

• What is the PL acheived (as tested or evaluated)?

  Select

• PL actual meets or exceeds PLr (PL required)

• PL actual does not meet PLr (PL required)

Machinery Normal Operation

• Verify that the Machine can be placed into a ready-to-run condition

  Yes

  No

  N/A

  Actions Required

• Initial Condition: Machine is Idle - contractors open , drives off

  Yes

  No

  N/A

  Actions Required

• Verify that all safety contactors are closed (Contactors and Pneumatic / Hydraulic Safety Valves are energised.)

  Yes

  No

  N/A

  Actions Required

• Verify all emergency stop pushbuttons are released, and door switches are in a safe state

  Yes

  No

  N/A

  Actions Required

• Verify that Safety Relay is healthy.

  Yes

  No

  N/A

  Actions Required

• Start the machine.

  Select

Fault testing Analysis of Safety Control System

Emergency Stops & Lanyard Switches

• Device ID

Testing Criteria

• As per AS 4024-2:2012 (EN ISO 13849-2:2012)

• Emergency Stops & Lanyard Switches SRPCS Testing

  Select Cross Short Test between input Channels (Cat 3 & 4) Input Channel Lost Signal (removal of one channel) 24vDC intrusion Earth Fault or 0v test where applicable

  • Cross Short Test between input Channels (Cat 3 & 4)
  • Input Channel Lost Signal (removal of one channel)
  • 24vDC intrusion
  • Earth Fault or 0v test where applicable

• Cross Short Test Result

  Pass

  Fail

• Details of failure and remedial action required.

• Input Channel Loss Test Results

  Pass

  Fail

• Details of failure and remedial action required.

• 24Vdc intrusion Test Results

  Pass

  Fail

• Details of failure and remedial action required.

• Earth Fault Test Results

  Pass

  Fail

• Details of failure and remedial action required.

Interlock Switches

• Device ID

• What type of switch is this?

  Select

Testing Criteria

• As per AS 4024-2:2012 (EN ISO 13849-2:2012)

• Interlock Switches SRPCS Testing

  Select Cross Short Test between input Channels (Cat 3 & 4) Input Channel Lost Signal (removal of one channel) 24vDC intrusion Earth Fault or 0v test where applicable

  • Cross Short Test between input Channels (Cat 3 & 4)
  • Input Channel Lost Signal (removal of one channel)
  • 24vDC intrusion
  • Earth Fault or 0v test where applicable

• Cross Short Test Result

  Pass

  Fail

• Details of failure and remedial action required.

• Input Channel Loss Test Results

  Pass

  Fail

• Details of failure and remedial action required.

• 24Vdc intrusion Test Results

  Pass

  Fail

• Details of failure and remedial action required.

• Earth Fault Test Results

  Pass

  Fail

• Details of failure and remedial action required.

ESPE Validation

• Device ID

Testing Criteria

• As per AS 4024-2:2012 (EN ISO 13849-2:2012)

• What type of ESPE are used on this machinery?

  Select Type 4 Safety Light Barriers (Res > 14mm) Finger Resolution Type 4 Safety Light Barriers (Res > 40mm<14mm) hand resolution Type 4 Safety Single Beam Sensors Type 4 Safety Light Curtains (Res <40mm) Safety Laser Scanner (Cat3,PLd) Type 2 Safety Light Curtains (Res >40mm<14mm) Hand Resolution Type 2 Safety Light Barriers (Res > 14mm) Finger Safety Bumpers - PLd Safety Edges - PLd Safety Mats - PLd

  • Type 4 Safety Light Barriers (Res > 14mm) Finger Resolution
  • Type 4 Safety Light Barriers (Res > 40mm<14mm) hand resolution
  • Type 4 Safety Single Beam Sensors
  • Type 4 Safety Light Curtains (Res <40mm)
  • Safety Laser Scanner (Cat3,PLd)
  • Type 2 Safety Light Curtains (Res >40mm<14mm) Hand Resolution
  • Type 2 Safety Light Barriers (Res > 14mm) Finger
  • Safety Bumpers - PLd
  • Safety Edges - PLd
  • Safety Mats - PLd

• Are safety stopping distances correct to prevent reaching the hazard? See standards such as AS4024:2801 for guidance

  Yes

  No

  N/A

  Actions Required

• Details of any limitations preventing correct placement with respect to AS4024:2801 or schedule action for relocation.

• Compliant

• Are safety devices mounted correct height above the floor or conveyor to protect against unauthorized entry - see ISO13855:2010 and AS4024:2801 for guidance

  Yes

  No

  N/A

  Actions Required

• Details of any limitations preventing correct placement with respect to AS4024:2801 or schedule action for relocation.

• Compliant

• Are ESPE's selected the correct type for the application?

  Yes

  No

  N/A

  Actions Required

• Is muting required on this set up

  Yes

  No

  N/A

  Actions Required

• Muting testing required

  Select Test Concurrent or Sequential Muting Test Override is not permanent Test Muting Lamp Feedback (where fitted) Light Curtains Revert to normal operation post mute

  • Test Concurrent or Sequential Muting
  • Test Override is not permanent
  • Test Muting Lamp Feedback (where fitted)
  • Light Curtains Revert to normal operation post mute

• ESPE Testing

  Select

• Removal of OSSD test

  Pass

  Fail

• Details of failure and remedial action required.

• Removal of Output Channel test<br>

  Pass

  Fail

• Details of failure

RESET & Feedback circuit testing

• Device ID

Testing Criteria

• RESET feedback circuit testing

  Select Removal of Feedback to Safety Relay / PLC Short Circuit of Feedback Auxiliary Contact Short Circuit of RESET Switch (Anti Tie Down Test)

  • Removal of Feedback to Safety Relay / PLC
  • Short Circuit of Feedback Auxiliary Contact
  • Short Circuit of RESET Switch (Anti Tie Down Test)

• Removal of feedback Test Result

  Pass

  Fail

• Details of failure and remedial action required.

• Short circuit of feedback Test Results

  Pass

  Fail

• Details of failure and remedial action required.

• Short circuit of RESET Test Results

  Pass

  Fail

• Details of failure and remedial action required.

Complementary Measures (other than ESTOPs)

• Device ID

Testing Criteria

• As per AS 4024-2:2012 (EN ISO 13849-2:2012) & EN574 III

• Complementary Safety Measures Used?

  Select Two Hand Controls Enable Switches - Hold To Run Safe Speed Monitoring Standstill Monitoring Foot Switches None Used

  • Two Hand Controls
  • Enable Switches - Hold To Run
  • Safe Speed Monitoring
  • Standstill Monitoring
  • Foot Switches
  • None Used

• For testing Two Hand Controls or Hold to Run Enable switches

  Select Hold one switch and after 1 second operate the second switch Operate both switch simultaneously - then release one switch

  • Hold one switch and after 1 second operate the second switch
  • Operate both switch simultaneously - then release one switch

• Machine does not start when tested like this

  Pass

  Fail

• When one switch is released the machine stops

  Pass

  Fail

• Simultaneity validation testing results

  Pass

  Fail

• Hold down test validation results

  Pass

  Fail

• Establish safe conditions and record test

  Pass

  Fail

• Confirm the Performance Level of the machinery as tested?

  Select

• Does this meet the requirement for the client and this type of machinery per standards?

  Yes

  No

  N/A

  Actions Required

• Confirm the Performance Level from the OEM / Integrator

  Select

• What if any improvements need to be made to establish the correct Performance Level

• Can the machinery be operated safely as tested?

  Yes

  No

  N/A

  Actions Required

• What immediate actions are recommended to allow machinery operation

Confirmation of Validation Result

• Overall Validation Testing Result

  Pass

  Fail

• Refer to action items list.

• Re-validated following completeion of action items

  Date

• Signed

  Sign

• Validated By

• Signature

  Sign

• Validated By

• Signature

  Sign