ANSI B11 STD B11.20-2017 Machine Tools - Safety Requirements for Integrated Manufacturing Systems.pdf

1、 ANSI B11.202017 American National Standard Safety Requirements for Integrated Manufacturing Sy stems ANSI-Accredited Standards Developer and Secretariat: B11 Standards, Inc. POB 690905, Houston, TX 77269 www.b11standards.org Approved: 12 SEPTEMBER 2017 by the American National Standards Institute B

2、oard of Standards Review COPYRIGHT PROTECTED DOCUMENT Copyright 2017 by B11 Standards, Inc. All rights reserved. Printed in the United States of America No part of this publication may be reproduced in any form, in an electronic retrieval system or otherwise, without the prior written permission of

3、B11 Standards, Inc. ii AMERICAN NATIONAL STANDARDS By approving this American National Standard, the ANSI Board of Standards Review confirms that the requirements for due process, consensus, balance and openness have been met by B11 Standards, Inc., (the ANSI-accredited standards developing organiza

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15、 competent professional in determining the exercise of reasonable care in any given circumstances. In addition to conforming to the requirements of this standard, the responsible personnel must also make an independent determination as to whether a machine, activity or condition complies with the ap

16、plicable legal requirements in the relevant jurisdiction(s). B11 Standards, Inc., has no power, nor does it undertake to police or enforce conformance to the requirements of this document. B11 Standards, Inc., does not certify, test or inspect products, designs, or installations for safety or health

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20、 You may contact the Secretariat for current status information on this, or other B11 standards. Published by: B11 Standards, Inc. POB 690905, Houston, Texas 77269, USA Copyright 2017 by B11 Standards, Inc. All rights reserved. Printed in the United States of America No part of this publication may

21、be reproduced in any form, in an electronic retrieval system or otherwise, without the prior written permission of the publisher. iii TABLE of CONTENTS PAGE FOREWORD . VII EXPLANATION OF THE FORMAT, AND ANSI B11 CONVENTIONS XI INTRODUCTION . XII 1 SCOPE 1 1.1 GENERAL 1 1.2 EXCLUSIONS . 1 2 NORMATIVE

22、 REFERENCES . 2 3 DEFINITIONS . 4 4 RESPONSIBILITY 11 4.1 SUPPLIER RESPONSIBILITIES . 11 4.2 USER RESPONSIBILITIES . 11 4.3 INTEGRATOR / MODIFIER / REBUILDER RESPONSIBILITIES 12 4.4 PERSONNEL RESPONSIBILITIES 12 5 RISK ASSESSMENT PROCESS 12 6 DESIGN, CONSTRUCTION, RE-CONSTRUCTION, AND MODIFICATION 1

23、5 6.1 GENERAL 15 6.2 LAYOUT DESIGN REQUIREMENTS 15 6.3 ELECTRICAL EQUIPMENT REQUIREMENTS 16 6.4 MODES OF OPERATION . 16 6.5 LOCAL CONTROL 18 6.6 ISOLATION OF POWER SOURCES 18 6.7 STORED ENERGY . 19 6.8 EMERGENCY MOVEMENT 19 6.9 PERFORMANCE OF THE SAFETYRELATED PARTS OF THE CONTROL SYSTEM . 20 6.10 Z

24、ONE STARTING/RESTARTING 20 6.11 EMERGENCY STOP 20 6.12 FLUID IMPACT ON OPERATING ENVIRONMENT AND EQUIPMENT . 21 6.13 MECHANICAL EQUIPMENT REQUIREMENTS . 21 6.14 RISK REDUCTION DESIGN REQUIREMENTS . 22 6.15 EJECTED PARTS OR FLUIDS . 23 6.16 STRUCTURAL INTEGRITY . 23 6.17 NOISE . 23 6.18 ERGONOMIC CON

25、SIDERATIONS. 24 6.19 LOCATION OF AWARENESS MEANS 24 6.20 ERRORS OF FITTING 25 6.21 LIFTING OF SYSTEM COMPONENTS 25 6.22 DOCUMENTATION REQUIREMENTS 25 6.23 REQUIREMENTS FOR REBUILD OR MODIFICATIONS 26 7 LAYOUT, INSTALLATION, TESTING AND START-UP . 27 7.1 GENERAL 27 7.2 LAYOUT 27 7.3 INSTALLATION 28 7

26、.4 TESTING AND START-UP 29 8 RISK REDUCTION MEASURES 30 8.1 GENERAL 30 8.2 RISK REDUCTION REQUIREMENTS 30 8.3 GUARDS . 31 8.4 ENGINEERING CONTROL DEVICES (SAFEGUARDING DEVICES) 31 8.5 AWARENESS MEANS . 32 iv 8.6 SPECIFIC HAZARDS 32 8.7 SAFE WORK PROCEDURES 33 8.8 SPAN OF CONTROL . 33 8.9 MUTING 34 8

27、.10 SAFETY-RELATED SENSING FIELD SWITCHING 34 8.11 SAFETY-RELATED SYSTEM RESET . 34 9 SET-UP, OPERATION AND MAINTENANCE 35 9.1 GENERAL 35 9.2 MACHINE SET-UP PROCEDURES . 35 9.3 OPERATION . 36 9.4 MAINTENANCE . 36 9.5 SUPERVISION 39 9.6 HAZARDOUS ENERGY CONTROL . 40 9.7 INITIATION OF NORMAL OPERATION

28、. 40 9.8 SAFETY SIGNS . 40 9.9 PERSONAL PROTECTIVE EQUIPMENT (PPE) 40 10 TRAINING 41 10.1 GENERAL 41 10.2 TRAINING ELEMENTS . 41 10.3 OPERATOR TRAINING 43 10.4 MAINTENANCE PERSONNEL TRAINING . 44 10.5 SUPERVISOR TRAINING . 44 10.6 RETRAINING. 44 11 DECOMMISSIONING PROCESS . 44 11.1 SUPPLIER RESPONSI

29、BILITIES . 44 11.2 USER RESPONSIBILITIES . 44 11.3 MODIFIER RESPONSIBILITIES . 45 11.4 DECOMMISSIONING TASK . 45 11.5 CONTROL OF HAZARDOUS ENERGY . 45 11.6 LAYOUT . 46 11.7 TRANSFER OF INFORMATION AND RISK 46 ANNEX A ILLUSTRATIVE EXAMPLES OF INTEGRATED MANUFACTURING SYSTEMS 47 ANNEX B EXAMPLES OF HA

30、ZARDS, TASKS, AND TASK/HAZARD PAIR LISTS GENERATED BY AN INTEGRATED MANUFACTURING SYSTEM RISK ASSESSMENT 52 ANNEX C PERFORMANCE OF THE SAFETY-RELATED FUNCTION(S) . 56 ANNEX D ZONE DETERMINATION AND SPAN OF CONTROL 57 D.1 GENERAL INFORMATION 57 D.2 SPECIFICATION OF LIMITS 60 D.3 TASK/HAZARD IDENTIFIC

31、ATION . 61 D.4 IDENTIFY TASK ZONES 63 D.5 SELECT RISK REDUCTION MEASURES . 64 D.6 IDENTIFY CONTROL ZONES 65 D.7 IDENTIFY SPAN(S) OF CONTROL . 66 D.8 EXAMPLES OF SPANS OF CONTROL 69 ANNEX E SPECIAL MODE 88 E.1 GENERAL . 88 E.2 CONSIDERATIONS ON RISK REDUCTION FOR SPECIAL MODE (SEE FIGURE E.1) 90 ANNE

32、X F GENERAL GUIDELINES FOR OPERATOR TRAINING . 92 v LIST of FIGURES PAGE Figure 1 Organization of the B11 series of documents . xii Figure 2 Typical clause layout of B11 base standards showing the various responsibilities xiv Figure 3 The risk assessment process 14 ANNEX A ILLUSTRATIVE EXAMPLES OF I

33、NTEGRATED MANUFACTURING SYSTEMS Figure A.1 Simple block diagram of an example IMS. 47 Figure A.2 IMS example using a robot as a material handling system . 48 Figure A.3 IMS example comprised of several zones 49 Figure A.4 Multi-zone IMS example with overhead gantry . 50 Figure A.5 IMS example of hor

34、izontal hydraulic extrusion press with integrated die carrier and butt shear . 51 ANNEX D ZONE DETERMINATION AND SPAN OF CONTROL Figure D.1 IMS example of horizontal hydraulic extrusion press with integrated die carrier and butt shear . 57 Figure D.2 The layout analysis process . 59 Figure D.3 Speci

35、fication of the limits of the IMS 60 Figure D.4 Identification of task locations and access requirements 61 Figure D.5 Identification of hazards / hazard zones and associated hazardous situations 62 Figure D.6 Identification of task zones. 63 Figure D.7 Selection of engineering controls . 64 Figure

36、D.8 Identification of control zones. 65 Figure D.9 Level of safety performance related to spans of control 68 ANNEX D EXAMPLE 1: SEPARATE ZONES WITHIN A SINGLE SAFEGUARDED SPACE Figure D.10a IMS with single safeguarded space 69 Figure D.10b Two control zones within single safeguarded space . 70 Figu

37、re D.10c Span of control of access doors . 71 Figure D.10d Span of control of conveyor system emergency stop device . 72 Figure D.10e Span of control of IMS emergency stop devices . 73 ANNEX D EXAMPLE 2: SUBDIVIDING THE SAFEGUARDED SPACE Figure D.11a IMS with divided safeguarded space 75 Figure D.11

38、b Additional access door (#4) between internal safeguarded spaces of the IMS 76 Figure D.11c Three control zones within the IMS 77 Figure D.11d Span of control of access door #1 78 Figure D.11e Span of control of access doors #2 Attention: B11 Secretariat or www.b11standards.org. Development This st

39、andard was prepared by the B11.20 Subcommittee, processed for comment/balloting by the B11 Accredited Standards Committee, and submitted for ANSI approval by the Secretariat. At the time of approval as an American National Standard, the ANSI B11 ASC was composed of the following Members: B11 Accredi

40、ted Standards Committee Leadership: Alan Metelsky, Chairman Barry Boggs, Vice-Chairman David A. Felinski, Secretary x Organizations Represented Names of Representatives Delegate Alternate Aluminum Extruders Council Mel Mitchell Chris Ebnet Armfield Harrison no deviation is permitted. The term “SHOUL

41、D” denotes a recommendation, a practice or condition among several alternatives, or a preferred method or course of action. Similarly, the term “CAN” typically denotes a possibility, ability or capability, whether physical or causal, and the term “MAY” typically denotes a permissible course of actio

42、n within the limits of the standard. B11 conventions: Operating rules (safe practices) are not included in either column of this standard unless they are of such nature as to be vital safety requirements, equal in weight to other requirements, or guides to assist in compliance with the standard. Whe

43、n B11 standards normatively reference either an external standard or an internal (intra-document) reference, they will use: “See X.” When B11 standards informatively reference either an external or internal (intra-document) reference, they will use: “See also, X.” The B11 standards generally use the

44、 term “OR” as an inclusive disjunction, meaning one or the other or both. When the term “and/or” is used, it means the same as the inclusive disjunctive “or” but is used by the writing subcommittee merely to emphasize the fact it is one or the other or both. B11 standards also draw a distinction bet

45、ween the terms “individual” and “personnel.” The term “individual” includes personnel (employees, subcontractors, consultants, or other contract workers under the indirect control of the supplier or user) but also encompasses persons who are not under the direct or indirect control of the supplier o

46、r user (e.g., visitors, vendors, etc.). xii Introduction The main purpose of every machine is to process materials. Inadvertent interference with, or accidental misdirection of released energy during production, maintenance, commissioning and de-commissioning can result in injury. The purpose of the

47、 ANSI B11 series of machinery safety standards is to devise and propose ways to eliminate or minimize risks of the potential hazards associated with the required tasks. This can be accomplished either by an appropriate machine design or by restricting personnel or other individuals access to hazard

48、zones, and by devising work procedures to minimize personnel exposure to hazardous situations. This is the essence of the ANSI B11 series of safety standards. This standard recognizes that zero risk does not exist and cannot be attained. However, a good faith approach to risk assessment and risk red

49、uction should achieve an acceptable risk level. Organization and Application of B11 Documents The B11 standards and technical reports can be associated with the ISO “Type A-B-C” structure as described immediately below, and as shown in Figure 1. Type-A standards (basis standards) give basic concepts, principles for design, and general aspects that can be applied to machinery; Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of engineeri