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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 Siemens SIRIUS Controls Ensures Cold Beer 1 400

Breweries are known for transforming malt, hops, and yeast into beer in gleaming brewing kettles and large fermentation tanks linked by numerous pipes.

Over the centuries, the equipment for mashing, lautering, boiling, and fermenting beer according to carefully guarded recipes has been steadily perfected.

 

The chiller is the heart of the brewery

One of the most important parts of the brewery, and perhaps the least visible, is the chiller. The fermentation temperature of the beer is crucial, which means that the heat generated by the yeast fermentation must be carefully controlled by the chiller.

If the beer ferments at too high a temperature, the yeast can produce a variety of undesirable aromas that ruin the beer.

According to Justin Thomas, President of G&D Chillers, based in Oregon

"The chiller is the heart of the brewery. Owners invest not only a lot of money in the brewery and brewing equipment, but also a great deal of time in the production of beer. But if the chiller fails, all that goes out the window."

Partnerships to keep pace with growth

Thomas says that growth at G&D Chillers has been exponential over the past 15 years. To continue this rate of success, the company had to look for new ways to meet customer demands for reliable, state-of-the-art chiller options.

For example, G&D Chillers recently teamed up with Siemens and the global distribution and supply chain solutions company WESCO to meet these needs and stay ahead of the competition. "We're still a small manufacturing company, but big enough to produce some technically advanced equipment," says Thomas. "We've always been service-oriented and always stood by our equipment, no matter what the problem. We get the same kind of support and service from Siemens that we give to our own customers."

 

Read more here 


 


Sponsored Content


Convenient Power Infeed and Distribution 

Siemens DCS Aug3 Kerwill CP Ad 2 300x250 copy

 

 

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.

 

 

To learn more, click here

 

 

 


 


 

Nationwide Equipment NetworkWhat’s the secret to providing superior service and staying competitive in a changing market? Well, you might learn something from ALTA Refrigeration’s experience. Over ten years, it transformed itself from a custom engineering services company into a scalable industrial equipment manufacturer, using an edge-oriented control architecture to efficiently manage a growing installed base.

 Originally started in 1975 as Industrial Refrigeration Services, ALTA has been designing and installing refrigeration systems across the United States for more than 45 years. And for a long time, they were large, custom-designed systems that used a central machine room to deliver refrigerant to various facility areas through long, overhead piping runs.

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International Application by PILZWhen the Swiss engineering company Peter Huber AG won the order to upgrade and convert the control and safety technology on manual-feed bending machines - to include an additional sheet metal feed via robot - alongside the requirements for economy, flexibility and efficiency there was also one key condition in the requirement specification: wherever possible, the envisaged solution should continue to use the existing controllers.

As cooperation between human, robot and machine presents a complex challenge not only in control terms but also regarding safety, an innovative solution was sought. Peter Huber found it in the modular safety relay myPNOZ.

 

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