Using Resources Carefully: Comprehensive environmental protection at Pilz

Whether we are talking about energy engineering, hazardous substances or instrument engineering: at Pilz, looking after the environment is a core part of the corporate philosophy. With the solar-powered building climate control system taken into operation last autumn, the company now also has sustainable ways to use energy.

At Pilz, sparing use of natural resources starts in the Central Purchasing department. Here, right at the start of the logistics chain, the company lays the foundations for active environmental protection. Purchasing guidelines designed to comply with the environmental requirements laid out in REACH (the future European Community Regulation on chemicals and their safe use) and RoHS (European Restriction of Hazardous Substances Directive) and evaluation of suppliers also on the basis of their environmental performance ensure that components and parts satisfy the relevant environmental standards.

Concern for the environment is also very much to the fore in the development of products. Already during development, issues are addressed such as whether a product can be designed more compactly so that, ultimately, energy and materials can be saved.

It is easy to think that this should be a simple matter, but once components start to get very compact they must not consume large amounts of energy. Otherwise they would get too hot. The PNOZsigma, for example, has been designed according to these criteria. The relay only uses increased amounts of energy during start-up, but during operation the energy saving circuitry comes into play. This ensures that overheating is impossible, and the desired energy saving effect is achieved.

Environmentally friendly manufacturing

Designing products to be environmentally friendly is just one side of the coin. The other is to manufacture them in a way which is environmentally sound. At Pilz, the implementation of environmentally aware production guidelines starts in the Production Engineering area: auxiliary materials are carefully selected according to their environmental compatibility. The use of unleaded solder for example is implemented on a voluntary basis in accordance with the RoHS guidelines. The alcohol-free, water-based flux materials for cleaning the circuit boards also contribute to this. In terms of environmental protection, this also means that fewer hazardous substances are stored in the company. Overflow troughs safeguard this storage so that potential risk of ground contamination is eliminated from the start.

Production itself is designed to be environmentally friendly, with sparing use of resources. For example, waste heat is used to operate the ventilation and air conditioning system. With the aid of heat exchangers, large amounts of energy can be saved in this case.

CO2 under control

Pilz is doing a number of things to reduce the company's carbon footprint: focusing lighting is one way to reduce CO2 emissions – without compromising the minimum brightness requirements stipulated for the workplace. Presence monitors ensure that the light is only switched on when it is actually needed. However, the biggest savings in terms of CO2 emissions have been made with the climate control technology which was taken into operation in 2008 and features state-of-the art engineering. The entire Peter Pilz Technology Centre is both heated and cooled via a solar heat plant. Energy efficiency has been significantly improved with the new system. Another measure is the gas heating which has been optimized with a new condensing boiler, which is now capable of heating two buildings at the same time.

Protecting the environment means taking responsibility

Today, every company also has a responsibility to other people and to the environment. Pilz understands this responsibility. This is why Pilz employees are sensitized for environmental concerns with the aid of various media, including for example the Intranet and special training sessions. This is because efficient environmental protection measures must be comprehensive.

A Brief Note About EU Standards

On their own, standards have no direct legal relevance until they are published in the Official Journal of the EU or are referenced in domestic laws and provisions. These are the publications by which a standard can acquire "presumption of conformity". Presumption of conformity means that a manufacturer can assume he has met the requirements of the corresponding directive provided he has complied with the specifications in the standard. So presumption of conformity confirms proper conduct. In a formal, legal context this is called a reversal of the burden of proof. Where the manufacturer applies a harmonized standard, if there is any doubt, misconduct will ned to be proven. Where the manufacturer has not applied a harmonized standard, he will need to prove that he has acted in compliance with the directives.

If a manufacturer does not comply with a standard, it does not necessarily mean that he has acted incorrectly. Particularly in innovative industries, relevant standards either may not exist or may be inadequate. The manufacturer must then demonstrate independently that he has taken the necessary care to comply with the safety objectives of the relevant directives. Such a route is usually more complex, but, in an innovative industry, it is often unavoidable.

It's important to stress that the EU does not publish every standard in the Official Journal, so many are still not harmonized. Even if such a standard is deemed to have considerable technical relevance, it will still not have presumption of conformity. However, sometimes a standard that has not been listed in the EU Official Journal does achieve a status that's comparable with harmonization. This is the case, for example, when a standard that's already been harmonized refers to the relevant standard. The standard that is not listed in the EU Official Journal is then essentially grandfathered into harmonization.

Ready to go?

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How can I manage situations where there are different assessments of the same risk by different machine builders?

Machine risk assessment is part qualitative, part quantitative requiring judgment by competent persons. Consequently there is likely to be a dispersion of the results achieved by different manufacturers or their authorized representatives when carrying out a risk assessment on the same or similar equipment. With the strength of the obligation in the directive machine builders may expect that machinery buyers and statutory authorities will seek more opportunity to examine the procedures followed, the assumptions and judgments made, and the results achieved.

Additionally the demands on machine builders to provide more detailed instructions will provide traceability between Risk Assessment and Instructions.

New Pilz website has more to offer!

Whatever the reason for undertaking a formal risk assessment on machinery or work equipment, Pilz consultants can provide an impartial service. Risk assessments are encountered in almost every walk of life, even for crossing the road. But when it comes to machinery, a formal risk assessment needs certain requirements to be fulfilled, and the person performing the risk assessment must be competent to do so.

While some companies have personnel who are competent to perform formal risk assessments on machinery, others appreciate that they lack the competence and therefore need support from consultants. There are also occasions when companies are busy and do not have the resources available when required, or they may choose to use an independent service provider for this critical task.

For any of these scenarios, the consultancy division of Pilz Automation Safety L.P. can undertake risk assessments on machines or machine designs in accordance with the requirements of relevant standards. Each assessment identifies the hazards present, estimates and evaluates the risks, and determines and outlines the measures that may be applied to reduce the risks to acceptable levels.

As part of the risk assessment, the consultants identify applicable standards, regulations and best industry practices, prepare a statement of the machine’s limits, and examine all hazards throughout the relevant machine lifecycle phases.

Because Pilz consultants have decades of experience of machine safety, their advice related to risk-reduction measures is particularly useful. This is in contrast to some other consultants that can highlight problems but are unable to advise on pragmatic, cost-effective risk-reduction measures.

Furthermore, if the client requires ongoing support, Pilz can provide engineering services to take the safety concept forward, and even supply products to implement a safety-related control and monitoring system. Alternatively, the client can take the consultants’ risk assessment report and carry out the necessary work in-house or work with a third-party supplier or system integrator of their choice.

For more information on the issues mentioned in this article please email marketing@pilzusa.com

For more information on Pilz Services please email consulting@pilzusa.com

Can I demand a copy of a risk assessment from the machine builder?

Certain social partners including European trade unions lobbied for a requirement that Risk Assessments be supplied with machinery to create more transparency and to compensate for such variations in assessment. However, it is not mandatory for machine builders to provide a risk assessment.

Safe Firing:

Is it correct that there is a new requirement relating to Risk Assessment?

In the existing directive:' The manufacturer is under an obligation to assess the hazards in order to identify all of those which apply to his machine; he must then design and construct it taking account of his assessment." The term Risk Assessment was not directly used in the directive but was referred to in harmonized standards EN1050 and more recently EN ISO 14121.

The iterative process of risk assessment is now enshrined unambiguously in the directive
The manufacturer of machinery or his authorized representative must ensure that a risk assessment is carried out in order to determine the health and safety requirements which apply to the machinery. The machinery must then be designed and constructed taking into account the results of the risk assessment...
...By the iterative process of risk assessment and risk reduction referred to above, the manufacturer or his authorized representative shall: eliminate the hazards or reduce the risk associated with these hazards by application of protective measures, in order of priority established..."

Idaho National Laboratory Utilizes Pilz Automation Safety L.P. for Protection

http://www.pilzamerica.com/articles/INL-One-Page-Reference-Sheet.pdf

Calculated Safety: SIL Calculation in accordance with IEC 61508/61511 in process-based applications

http://www.pilzamerica.com/articles/Calculated-Safety.pdf

the New Directive?

Can manufacturers CE mark machinery under the new Machinery Directive in advance of this date?

From the legal point of view, machinery can only be placed on the market with reference to Directive 2006/42/EC as of December 29, 2009. However, in general, the essential requirements are at least as stringent, therefore machine builders should review their products without delay and prepare to adapt them as necessary to take account of the requirements of the new Directive. Pilz provides a conformance assessment service to determine the gaps a machine manufacturer may face in bringing existing designs into compliance.

How will the new machinery directive be enforced?

Freedom of movement of machinery is guaranteed with the "passport of the CE mark". As most machines are placed on the market without independent certification by notified bodies, surveillance is essential to the fair and effective operation of the single market for the supply of machinery. Directive 98/37 dopes not use the term "market surveillance". However, in the new MD the framework for market surveillance is now clearly stated ina new Article 4 specifically dealing with this aspect.

• member states must take measures against non-complying products
• there must be a known national competent authority
• tasks and powers of such authority must be clearly defined and transparent

Properly applied, this strengthening of the "policing" aspects will ensure a fair market place with a high standard of safety. In addition, such authorities in each member state are obliged to consider machines that may be unsafe when used for their intended purpose but also machines that could be unsafe "under conditions which can reasonably be foreseen".

Click to view Trends and Developments of HMIs

http://www.pilzamerica.com/articles/Trends-and-DevelopmentsofHMIs.pdf

Buhler Inc. and Pilz Automation Safety L.P. Partner for Safety

(CANTON, MI) – Buhler Inc. of Plymouth, Minn. has partnered with Pilz Automation Safety L.P. of Canton, Mich. to implement safety in its flour heat treatment, brewing and malting equipment. Buhler Inc. installed PNOZmulti modular safety systems to control explosion vents and emergency stops. This system will protect personnel and equipment from being harmed or destroyed during a deflagration. The PNOZmulti m1p allows for easy expansion as well as an improved response time of approximately 40ms. Download PDF Reference: http://www.pilzamerica.com/articles/INL … -Sheet.pdf

Pilz Automation Safety L.P.

The world leader is SAFE automation; Pilz offers a full range of leading-edge safe automation products and services. The company’s innovative technologies and safety expertise provides customers with the leanest and safest solutions.

Buhler Inc.

Buhler is a global leader in the supply of process technology, especially production technologies for making foods and engineering materials. Buhler is active in over 140 countries and has some 7000 employees worldwide. In fiscal 2008, the Group generated sales of CHF 1893 million.

My company receives machinery from our parent company in the USA. What are the implications of the new machinery directive?

You need to ensure that the machine conforms to all applicable directives including the new machinery directive. Additionally, you need to designate a person established in the community to be responsible for the compilation of the technical construction file. This could be a competent person in your own organization or a third party you appoint.

Calculations without the headache Software tool verifies the functional safety of protection devices on machinery

Canton, MI – Pilz Automation Safety’s software tool, PAScal, verifies the functional
safety of protection devices on machinery in light of current standards. The Safety
Calculator supports manufacturers in the calculation of failure limit values, as required by
standards IEC 62061 and prEN ISO 13849-1. The software tool enables a reduction in
costs and the amount of time spent on the task, particularly as figures need to be
recalculated each time the safety functions are modified.
The PAScal Safety Calculator separates the safety functions into their component parts,
calculates the overall probability of a dangerous failure per hour (PFHD value) and
verifies the data with the prescribed performance level or safety integrity level. The
software tool also takes into account potential architectures and variations if subcomponents
are connected together and parameterized.

Division into sub-systems
According to the approach of IEC 62061 (sector standard from IEC 61508 for safety in
machine control systems), safety-related functions are divided into sub-systems such as
sensors, inputs, logic, outputs and actuators. So the architecture for each sub-system can
be specified separately. The sub-systems can be combined as required.The Safety Calculator not only considers the factors listed in prEN ISO 13849-1 for
evaluating the common cause failure (CCF), but also takes into account the parameters
that depend on logic or electronics, which affect diagnostic coverage (DC). These include
detection of shorts between contacts or synchronicity monitoring on multi-channel
sensors, for example.

Based on a database
The basis for the Safety Calculator is a comprehensive database that already contains
details of Pilz products. Users can also define their own components and store them in the
database, provided the necessary numeric values are known. The Safety Calculator uses
this data to calculate the PFHD value.
The PAScal Safety Calculator provides support to manufacturers when designing safetyrelated
control elements. For new design procedures are required now that EN 954-1 has
been replaced by prEN ISO 13849-1 for the design of safety-related control systems and
standard IEC 62061 has been published.
The software tool also allows for the flexibility that engineering requires. Safety
functions can change from machine to machine, so that calculations need reworking
again and again. The Safety Calculator absorbs the associated costs.

What is an authorized representative?

The machinery directive anticipates that machine builders may require appointing competent persons to carry out some or all of the administrative and assessment procedures required to CE mark a machine. The new machinery directive defines an authorize representative as "...any natural or legal person established in the Community who has received a written mandate from the manufacturer to perform on his behalf all or part of the obligations and formalities connected with this directive..."