CONTENTS

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In this training, it will be explained with examples how machinery safety risk assessment analyzes are made within the framework of the standards related to the 2006/42 EU Machinery Safety regulation.

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a)   EU Approaches to Quality and Product Reliability

     •   Classical Approach (Old Approach)

     •   New Approach

     •   Global Approach

     •   Modular Approach

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b)   CE process and basic concepts

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c)   EU technical legislation harmonization studies

     •   Machinery Safety Directives (98/37/EC, 2006/42/EC) differences

     •   Machinery Safety Directive - 2006/42/EU

     •   2006/42 EU Changes in definitions

     •   Areas of Application and Non-Application

     •   Employer Obligation and Risk Assessment

     •   CE Conformity Assessment Modules

     •   How should the content of the technical file be

     •   How to accept machine and technical file review

     •   “EU Declaration of Conformity” examination in machine acceptance (How should the appropriate declaration be?)

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d)   EU Conformity Assessment Process for Machinery and Safety Equipment

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e)   Machine Acceptance Criteria -2006/42 EC Question List

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f)     Causes of Machine Induced Work Accident

     •   Man-made hazards

     •   Design hazards

     •   electrical hazards

     •   Physical and chemical hazards

     •   Sample accident investigations

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g)   What is ANTHROPOMETRICS?

     •   Anthropometry definition

     •   Features of Human Machine Systems

     •   Hand and arm reach distances

     •   Foot and leg reach distances

     •   Response times of perception organs

     •   Lighting and temperature influence

     •   Upper body and lower body movements

     •   Sample accident investigations

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h)   Machine Protective Systems

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I)     Machine Acceptance Criteria

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j)     Machinery Safety Standards

     •   EU Standardization Bodies

     •   EU Standards – Differences between EN –PrEN-HD-TS and TR EU Standards

     •   What is the Traffic Light Configuration of EU standards?

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k)   What is Machinery Safety Risk Assessment? Steps

     •   STAGE I: Gaining knowledge about the machine environment and application

     •   II. STAGE: Assessment of total risk

     •   III. STEP 1: Risk reduction

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l)     What is “Functional Security”?

     •   Differences between IEC 61508, EN 954, DIN V 19250 and DIN V VDE 0801 Standards

     •   EN/IEC 61508: Electrical/electronic/programmable electronic system functional safety of safety-related parts

     •   EN/IEC 61511: Functional safety – Safe instrument systems for the process industry sector

     •   EN/IEC 62061: Safety of machinery – Functional safety of electrical, electronic and electronic control systems of safe parts

     •   EN 954: Machinery safety – Safety-related parts of the control system

     •   EN ISO 13849: Machinery safety – Safety-related parts of the control system

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m)  Machinery safety: It will be described in terms of differences in the old standard EN 1050 and EN14121.- Risk assessment according to EN 13849 - EN 12100

     •   Danger zones: definitions, examples

     •   Control system categories according to EN 12100 (Former EN954-1)

     •   Risk assessment, selection of control system category

     •   Selection of protection type according to EN 13849 (Former EN292) standard

     •   Safety circuits specifications B 1,2,3,4

     •   Example of EN 13849 RISK ASSESSMENT application explanation,

     •   Press, surface grinder risk assessment example,  

     •   Plastic injection machine risk assessment example,

     •   Example of automatic feeding circular saw risk assessment,

     •   Dyeing bench risk assessment example,

     •   Warehouse area automatic robot arm risk assessment example etc. application examples

     •   Mean Time to Dangerous Error (MTTFd)

     •   Degree of Diagnostic (DC)

     •   Determining the PL Value of the Subsystem

       Example applications

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n)   EN/IEC 62061: Machinery safety – How is the functional safety of electrical, electronic and electronic control systems of safe parts made risk assessment?

     •   What is SIL (Safety Integrity Level)?

     •   How to find SIL?

     •   Reducing risk

     •   PLC, sensors and starters etc. “Safety Function” selection

     •   Risk assessment examples (filling machine etc.)

     •   Possibility of dangerous random hardware failure (PFHd)

     •   Hardware Fault Tolerance (HFT)

     •   Safe Interruptions Allocation (DC/SFF)

     •   Common Reasons Outage (CCF)

     •   Conclusion – Determining the SIL Value for the Subsystem

       Sample Application

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o)   Selection of Protective Systems Standards

     •   Danger zone,

     •   What is a Person Exposed?

     •   What are Safety Distances?

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p)   Safety Distances Standard explanation

     •     Detection distance calculation according to the type and location of safety devices  

     •     Two-handed button and sensing distance calculation based on location  

     •     Detection distance calculation based on the type and location of the beam barriers  

     •     Detection distance calculation based on safety carpets and location  

     •   Minimum detection area

     •   Example explanations

     •   ANSI B11.19-2003 explanation of Safety Distances Standard

     •   Detection distance calculation based on the type and location of the beam barriers  

     •   Two-handed button and sensing distance calculation based on location  

     •   Example explanation

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q)   EN ISO 13857Protection Area Height and Barrier Spacing

     Calculation of safety distance

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