Hydrocharger safety upgrade according to ISO 13849-1: from analysis to implementation!
- Consumer goods
- Industrial electrical engineering
- PLC / PC programming
Machine safety is a crucial factor in every modern production environment. Besides reducing the risk of occupational accidents, a compliant safety concept is necessary to comply with the European Machinery Directive. For an existing hydrocharger installation in the production process of a customer in the filter industry, it was found internally that the installation no longer met current safety regulations. Elenco was called in to handle the entire process, from risk analysis to implementation, with the aim of upgrading the installation to a compliant and safely operating machine.
Safety analysis
The machine in question, a hydrocharger installation, had been part of the production process for years but showed several shortcomings in terms of machine safety. The installation was originally not equipped with safe zone separation or access monitoring, a certified emergency stop system or standardised safety sensors. That is why we carried out a complete risk analysis according to ISO 13849-1, focusing on electrical and mechanical risks. Among other things, the analysis covered:
- Operation and accessibility of the installation;
- Earthing and equipotential bonding;
- Assessment of existing mechanical guards and maintenance hatches;
- Checks for correct pictograms and instructional and safety signage;
- Evaluation of the safety architecture of the existing control system;
- Inventory of individual risks per part of the installation;
- Definition of the required Performance Levels (PLr) per safety function.
Based on the analysis report, a technical plan was drawn up for the necessary safety measures. This resulted in a complete solution, including hardware changes, control modifications and system integration.
Technical upgrade and integration
The safety upgrade was scheduled to have minimal impact on ongoing production. The main technical interventions were as follows:
Control and automation
- Integration of a Siemens S7-1515 with failsafe functionality in the existing control cabinet;
- Design and installation of a new cabinet equipped with SIMATIC ET 200SP I/O modules;
- Integration of existing and new frequency converters with a safe stop function;
- Addition of safety contactors to block dangerous movements when someone enters the machine.
Physical safety provisions
- Installation of safety fencing with secured access (door switches with status monitoring);
- Use of floor scanners to detect unauthorised access to hazardous zones;
- Integration of a safety reset function linked to access monitoring;
- Strategically placed emergency stop buttons and pull-cord systems, linked to a certified safety relay;
- Installation of a local maintenance isolator with a feedback contact at every electric motor.
Software and programming
- Programming of the safety logic in TIA Portal, including failsafe routines and diagnostic functions;
- Integration of a floor plan on the HMI showing all safety sensors, to quickly find and resolve the cause of an emergency stop;
- Configuration of frequency converters with safe functions.
Interested in a similar safety upgrade?
We support manufacturers in analysing, advising on and implementing tailor-made safety solutions. From risk analysis to implementation, Elenco delivers safe and workable solutions that meet all relevant standards.
Wondering whether your installation meets current safety standards? Get in touch with us and we will gladly come and assess your current situation.
