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 Juy 18, 2022

 

DCS IEC 62061 Safety Integrated Level by PILZ 1 400

Functional safety in accordance with IEC 62061

IEC 62061 / EN IEC 62061 represents a sector-specific standard under IEC 61508. It describes the implementation of safety-related control systems on machinery and examines the whole lifecycle from the concept phase through to decommissioning.

The new edition of IEC 62061 was published in 2021. This new edition is not just an update of the existing standard. For a start, the standard is no longer limited to electrical systems but can be used for all types of technology, such as hydraulic or pneumatic systems for example.

IEC 62061:2021 harmonized as EU standard EN IEC 62061:2021!

In April 2022, IEC 62061 was published in the Official Journal of the EU as harmonized standard EN IEC 62061, the content being identical.

DCS IEC 62061 Safety Integrated Level by PILZ 2 400

As a result, presumption of conformity has officially come into force within the EU. A manufacturer can assume that he meets the health and safety requirements of the Machinery Directive if he complies with the provisions of the EU standard. In the conformity assessment procedure, he can issue the declaration of conformity and so affix the CE mark to his plant or machinery.

Presumption of conformity for the previous version EN 62061:2005 ends on 11 October 2023 at the latest! After this transition period, new declarations of conformity can only be issued on the basis of EN IEC 62061:2021.

The European Commission announced the newly harmonized standards on the EU website with CID 2022/ 621, dated April 2022. As of May 2022, they have not yet been published by the EU Commission in the informal "Summary List"!

To read about the procedure for publishing harmonized standards in the EU, click here 

 

DCS IEC 62061 Safety Integrated Level by PILZ 5 400

You can also listen to the PILZ podcast "For Your Safety" to hear about the "Updates to the Standard IEC 62061" by clicking here 

 

Important changes to IEC 62061 / EN IEC 62061:

  • •Changes to the methodology used to define the required SIL level
  • •The need to draft a Safety Requirements Specification
  • •The option to use devices developed in accordance with other standards
  • •More details on safety-related application software

 

 

Contents of IEC 62061

DCS IEC 62061 Safety Integrated Level by PILZ 3 400

IEC 62061 addresses the issue of how reliable a safety-related control system needs to be. In this case the estimation is based on a hybrid method, a combination of a matrix and a quantitative approach. It also addresses the validation of safety functions based on architectural and statistical methods.

As with EN ISO 13849-1, the objective is to establish the suitability of safety measures to reduce risks. Even with this standard, extensive calculations are required. You can significantly reduce the work involved by using appropriate software such as the Safety Calculator PAScal.

 

How do you determine the required safety integrity in accordance with IEC 62061?

For each risk requiring a safety-related control system, the risk must be estimated, and the risk reduction (SIL) defined, dependent on the control system. The risk associated with the safety function is estimated in accordance with IEC 62061, with consideration given to the following parameters:

  • •Severity of injury (Se)
  • •Frequency and duration of exposure (Fr)
  • •Probability of occurrence of a hazardous event (Pr)
  • •Probability of avoiding or limiting harm (Av)

 

SIL classification in accordance with IEC 62061

Classification of severity (Se)

Consequences

Severity (Se)

Irreversible: death, losing an eye or arm

4

Irreversible: broken limb(s), losing a finger(s)

3

Reversible: requiring attention from a medical practitioner

2

Reversible: requiring first aid

1

 

Classification of the frequency and duration of exposure (Fr)

Frequency of exposure

Duration (Fr) <= 10 min

Duration (Fr) > 10 min

≥ 1 per h

5

5

< 1 per h up to ≥ 1 per day

4

5

< 1 per day up to ≥ 1 every 2 weeks

3

4

< 1 every 2 weeks up to ≥ 1 per year

2

3

< 1 per year

1

2

 

Classification of probability (Pr)

Probability of occurrence

Probability (Pr)

Very high

5

Likely

4

Possible

3

Rarely

2

Negligible

1

 

Classification of probability of avoiding or limiting harm (Av)

Probability of avoiding or limiting

Avoiding and limiting (Av)

Impossible

5

Rarely

3

Probable

1

 

What is determination of the required Safety Integrity like in accordance with IEC 62061?

Assignment matrix for determining the required SIL (or Plr) for a safety function

DCS IEC 62061 Safety Integrated Level by PILZ 4a 400

EXAMPLE: For a specific hazard where Se = 3, Fr = 4, Pr = 5 and Av = 5, then:
Cl = Fr + Pr + Av = 4 + 5 + 5 = 14
Using this table would lead to a SIL 3 or PL e being assigned to the safety function that is intended to mitigate the specific hazard.

 

How do you design a safety function?

For each safety function it is necessary to identify the critical elements for performing the function, the so-called subsystems. The selection or design of these subsystems must cater for a SIL which is equal to or higher than the required level. The combination of all of these subsystems must also enable you to reach the required SIL.

Each subsystem must meet the following requirements:


- Architectural constraints for hardware safety integrity
- Probability of dangerous random hardware failures (PFH)
- Systematic safety integrity (requirements for avoiding failures and requirements for controlling systematic faults)

 

Architectural constraints of a subsystem

The SIL value that subsystems achieve is influenced by the architecture of the control system and the "Safe failure fraction" (SFF) or diagnostic level.

Safe failure fraction
(SFF)

Hardware fault tolerance
HFT 0

Hardware fault tolerance
HFT 1

Hardware fault tolerance
HFT 2

< 60 %

Not permitted, unless well-tried components

SIL 1

SIL 2

60 % to < 90 %

SIL 1

SIL 2

SIL 3

90 % to < 99 %

SIL 2

SIL 3

SIL 3

>= 99 %

SIL 3

SIL 3

SIL 3

HFT: Hardware fault tolerance
SFF: Safe failure fraction

 

Requirements for the probability of dangerous random hardware failures

The probability of a dangerous failure of any safety-related control function (SRCF) because of dangerous random hardware failures shall be equal to or less than the failure threshold value defined in the safety requirements specification.

SIL level in accordance with IEC 62061

Probability of a dangerous failure per hour (PFHD) [1/h]

SIL 3

>= 10 E-8 to < 10 E-7

SIL 2

>= 10 E-7 to < 10 E-6

SIL 1

>= 10 E-6 to < 10 E-5

 

Why not try PILZ’s calculation tool (PAScal), which you can use to determine the relevant characteristic values with ease?

 

Further information:

Their experts will be happy to support you with the implementation of IEC 62061, thereby ensuring safe operation of your plant and machinery.

To learn more about PILZ services for automation, plant, and machinery safety, click here 

To use their Safety Calculator PAScal – Calculation tool for verifying functional safety, click here 

PILZ Logo 300x150

 

 

Source

 


Editor's Pick: Featured Article


DCS Lafert Formally Introduces New Plant in San Dona di Piave 1 400x275

The new production plant is officially in operation after its formal unveiling at Lafert’s 60th anniversity celebrations in San Donà di Piave, Italy, close to the historic headquarters. 

The 130 000 sq foot plant was developed to increase production capacity and meet the growing demand for IE5 Super Premium Efficiency motors, while also providing new storage areas for raw materials and finished products. In this plant alone, Lafert is able to produce up to 1400 pieces per day and can ship 4-5 international containers per week thanks to the internal customs area. 

The project began in September 2020 with the aim of building a brand-new manufacturing plant to produce high efficiency permanent magnet motors, specifically intended for pumping applications. The plant was designed and built with extensive automated production capabilities including fully automated production lines. Today the plant employs 50 operators who have been carefully trained to work in synergy with the production lines. The plant delivers maximum comfort in the working conditions of the operators in terms of light, space, services, and other factors that affect the well-being of employees. 

 

To read more about this challenge, and the solution, click here 


 


Sponsored Content


Convenient Power Infeed and Distribution 

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The 3RV29 infeed system is based on a basic module complete with a lateral incoming supply unit (three-phase busbar with infeed). Expansion modules (three-phase busbars for system expansion) are available for extending the system.

 

 

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DCS Sonepar Acquires Aztec Electrical Supply 1 400x275

Sonepar has announced that its wholly-owned Canadian subsidiary, Sonepar Canada, Inc. has acquired Aztec Electrical Supply Inc. (“Aztec”). With a strong presence in the province of Ontario, the acquisition of Aztec will strengthen Sonepar’s ability to grow their industrial business model across the Greater Toronto Area.

Founded in 2002, Aztec expanded its market presence across Ontario opening four branches located within Vaughan, Cambridge, Mississauga, and Burlington. Aztec will add over 100 associates to the Sonepar network in Canada and is expected to record sales revenues of over $70 million in 2022.

 

Read more here


 

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New Product

DCS New LUTZE DRIVEFLEX and MOTIONFLEX VFD Cables from Automation Direct 1 400x275

AutomationDirect has added new LUTZE DRIVEFLEX® and MOTIONFLEX® variable frequency drive cables which provide supreme protection against electromagnetic interference (EMI).

These cables are available in 18 to 8 AWG sizes and include four black conductors with a green/yellow ground conductor of the same gauge. Each conductor is labeled for easy identification and is covered in a cross-linked Polyethylene (XLPE) insulation (type XHHW-2) that is oil and sun resistant, suitable for dry, damp, or wet locations, and approved for direct burial.

The DRIVEFLEX series has a black PVC outer jacket ideal for stationary applications, while the MOTIONFLEX series has a black thermoplastic elastomer (TPE) outer jacket designed for continuous motion applications. Both cables are tray cable-exposed run rated (TCER) for use in cable trays with or without conduit, which can significantly reduce installation costs.

The new DRIVEFLEX series cable starts at $2.58 /ft. and the MOTIONFLEX series cable starts at $3.67 /ft.  Both cables are made in the USA and can be ordered cut to length in 1-foot increments with a 10ft minimum.


To read more, click here


 


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DCS Omrons New Integrated Controller Capable of Controlling Robots and Entire Automation Systems 1 400x275

Omron has recently introduced its most full-featured machine automation controller to date. Offering control of multiple robots, the choice of 16, 32, or 64 controlled motion axes, and SQL connectivity. It is the ideal control solution for complete robotic cells, high-speed motion systems, material handling and multi-robot systems.

The Robotics Integrated Platform is the next revolutionary step in the SYSMAC ecosystem that seamlessly integrates the full Omron Fixed Robotics product line. Their one controller approach integrates robot control, in addition to sequence and motion control, to a single controller. This enables synchronized control of robots as well as other devices and results in higher performance compared to typical network based configurations. It also enables users to collect information on devices aligned to a common timeline which not only improves overall system response times and accuracy but also greatly aids in troubleshooting activities.


To read more, click here


 

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