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GB/T 38272-2019: Safety of machinery - Guidelines for safety upgrading of machinery
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Safety of machinery - Guidelines for safety upgrading of machinery
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GB/T 38272-2019
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Basic data | Standard ID | GB/T 38272-2019 (GB/T38272-2019) | | Description (Translated English) | Safety of machinery - Guidelines for safety upgrading of machinery | | Sector / Industry | National Standard (Recommended) | | Classification of Chinese Standard | J09 | | Classification of International Standard | 13.110 | | Word Count Estimation | 18,138 | | Date of Issue | 2019-12-10 | | Date of Implementation | 2020-07-01 | | Issuing agency(ies) | State Administration for Market Regulation, China National Standardization Administration | GB/T 38272-2019: Safety of machinery - Guidelines for safety upgrading of machinery---This is a DRAFT version for illustration, not a final translation. Full copy of true-PDF in English version (including equations, symbols, images, flow-chart, tables, and figures etc.) will be manually/carefully translated upon your order.
Safety of machinery -- Guidelines for safety upgrading of machinery
ICS 13.110
J09
National Standards of People's Republic of China
Machinery Safety Machinery Equipment Safety Upgrade Guide
Published on.2019-12-10
2020-07-01 Implementation
State Administration for Market Regulation
Released by the National Standardization Administration
directory
Preface III
Introduction IV
1 Scope 1
2 Normative references 1
3 Terms and Definitions 1
4 Security upgrade process 1
5 Risk Assessment 2
6 Security upgrade plan 3
6.1 Overview 3
6.2 Adoption of risk reduction measures specified in Category C standards3
6.3 Applying the Risk Reduction Process Iterative Three-Step Method to Select Risk Reduction Measures 3
6.4 Consideration of safety-related control systems5
7 Security upgrade design 5
7.1 Principle 5
7.2 Design method 5
8 Security Upgrade Implementation 7
8.1 Overview 7
8.2 Qualifications7
8.3 On-site construction 7
9 Security Upgrade Confirmation7
9.1 Confirmation of safety precautions7
9.2 Confirmation of safety function 7
9.3 Validation of safety-related control systems 7
9.4 Confirmation of residual risk7
9.5 Identification of new risks7
9.6 Archives 7
Appendix A (Informative Appendix) Class B Standards Commonly Used in Security Upgrade Design 9
Reference 12
Machinery Safety Machinery Equipment Safety Upgrade Guide
1 Scope
This standard provides the terms and definitions for the safe upgrade of mechanical equipment, and provides guidelines for the safe upgrade of mechanical equipment.
This standard applies to the safety upgrade of in-service machinery and equipment.
This standard does not apply to mechanical equipment that has been specifically stipulated by national laws and regulations, such as special equipment.
2 Normative references
The following documents are essential for the application of this document. For dated references, only the dated version applies to this article
pieces. For undated references, the latest edition (including all amendments) applies to this document.
GB/T 15706-2012 General Principles of Mechanical Safety Design Risk Assessment and Risk Reduction
GB/T 16855.1-2018 Safety-related parts of machinery safety control systems - Part 1.General rules for design
GB/T 16855.2 Safety-related components of machinery safety control systems - Part 2.Confirmation
3 Terms and Definitions
The terms and definitions defined in GB/T 15706-2012 and the following terms and definitions apply to this document.
3.1
machinery equipment
A combination consisting of several parts and components connected with a specific application purpose, at least one of which is movable, and
Equipped or scheduled to be equipped with a powertrain.
Note. The "mechanical equipment" defined by this term is equivalent to the "machine" defined by the term 3.1 in GB/T 15706-2012.
3.2
safetyupgradingsafetyupgrading
Based on the results of risk assessment, activities to reduce the risk of mechanical equipment through technical means.
3.3
acceptable risk tolerablerisk
The level of risk that is acceptable under given conditions, based on current societal values.
[GB/T 35080-2018, Definition 3.2]
4 Security upgrade process
The security upgrade process (see Figure 1) consists of the following 5 steps.
a) risk assessment;
b) Security upgrade plan;
c) Safety upgrade design;
d) Security upgrade implementation;
e) Security upgrade confirmation.
5 Risk Assessment
Security upgrades should be based on the results of the risk assessment.
Since the Class C standard identifies significant hazards commonly associated with a class of machinery and equipment, and gives the safe handling of these hazards
requirements and/or risk mitigation measures. Therefore, if the mechanical equipment or similar mechanical equipment has the corresponding C standard (machine product safety standard
Standard), it is advisable to directly target the major hazards identified by the corresponding C standard, and formulate a safety upgrade plan according to the requirements of the C standard (see 6.2),
And carry out safety upgrade design (see 7.2). For other hazard sources not covered by the C standard, it should be based on GB/T 15706-2012
Chapter 5 conducts risk assessment.
For mechanical equipment that does not correspond to Class C standards, risk assessment should be carried out in accordance with Chapter 5 of GB/T 15706-2012.
After the risk assessment is completed, the identified hazard sources that need to be reduced should be recorded in Table 1, and compiled to meet the requirements of GB/T 15706-
Risk assessment report for the relevant requirements of Chapter 7 in.2012.
6 Security upgrade plan
6.1 Overview
Appropriate risk reduction measures should be selected based on the results of the risk assessment and technical feasibility, and a safety upgrade plan should be formulated to enable the mechanical equipment.
to an acceptable level of risk.
When choosing risk reduction measures, it is advisable to seek the opinions of personnel engaged in mechanical equipment operation, debugging, maintenance, repair, etc.
The impact of normal use of mechanical equipment is minimized.
According to the hazard sources listed in Table 1, the corresponding risk reduction measures should be determined respectively (see 6.2~6.4) to form a safety upgrade plan. if
Risk reduction measures need to rely on safety-related control systems to achieve corresponding safety functions, and also need to be based on GB/T 16855.1-2018
Appendix A in the determination of the required performance level (PLr) for safety-related control systems.
6.2 Adopt the risk reduction measures specified in the C standard
Adoption of the risk reduction measures specified in the C standard can be regarded as an acceptable level of risk through sufficient risk reduction. in the exact
When deciding on risk reduction measures, the C standard should be given priority.
If the Class C standard provides several optional risk reduction measures, but does not specify the selection principle, it should be based on the specific risk assessment results.
Choose appropriate risk reduction measures.
6.3 Applying the Risk Reduction Process Iterative Three-Step Method to Select Risk Reduction Measures
There are no Class C standards for machinery or similar mechanical equipment, and hazards not covered by Class C standards, if it is necessary to take a risk
If the risk reduction measures are not taken, then when formulating the security upgrade plan, the three steps of the risk reduction process given in Figure 1 in GB/T 15706-2012 should be iterated.
method to select appropriate risk reduction measures. Table 2 from hazard elimination, risk factors (severity of injury, personnel exposure to hazard, hazardous event
The three-step method of selecting risk reduction measures according to the iterative three-step method of the risk reduction process is given.
guide.
6.4 Consideration of safety-related control systems
If the safety protection devices (such as interlocks, emergency stop devices, etc.) used in the risk reduction measures need to rely on the control system to achieve their safety
If it is fully functional, the safety-related control system should be designed according to GB/T 16855.1-2018 when making a safety upgrade plan.
7 Safety upgrade design
7.1 Principles
The ultimate goal of security upgrades is to minimize risk.
The safety upgrade design should be based on the hazards identified in the safety upgrade plan and the corresponding solutions, in accordance with the provisions of the corresponding Class C standards
And/or the design principles determined in GB/T 15706-2012, and complete the design item by item in combination with relevant standards.
If there is a Class C standard, the safety upgrade design should be carried out in accordance with the safety requirements and/or risk reduction measures specified in the Class C standard.
When the requirements of Class C standards are different from those of Class A standards or Class B standards, the requirements of Class C standards are given priority.
If there is no Class C standard or the Class C standard does not provide clear risk reduction measures, the safety upgrade design should be carried out in accordance with 7.2.
7.2 Design method
7.2.1 Overview
Figure 1 in GB/T 15706-2012 presents an iterative three-step approach to the risk reduction process. In order to take full advantage of the available technology to
To reduce the risk, this process should be carried out several times in a row if necessary.
The following four factors should be considered when undertaking the risk reduction process.
a) safety at all stages of the life cycle of machinery;
b) the ability of the mechanical equipment to perform its function;
c) ease of use of mechanical equipment;
d) After the safety upgrade, the cost of mechanical equipment operation and subsequent disassembly.
Appendix A gives the commonly used Type B standards in the design of security upgrades.
7.2.2 Intrinsically safe design
The intrinsically safe design should meet the requirements of 6.2 in GB/T 15706-2012 and the requirements of the relevant Class B and/or Class C standards.
If it involves major changes to the structure of the mechanical equipment, the original design data of the mechanical equipment should be obtained.
7.2.3 Safety protection and supplementary protection
7.2.3.1 Safety guards
The design or selection of safety guards should meet the requirements of relevant Class B standards, such as the guards that meet GB/T 8196,
Interlocking device of GB/T 18831.
The design or selection of safety guards should be suitable for the intended use, taking into account the associated mechanical and other hazards. safety gear
It should be coordinated with the working environment of the machinery and equipment, and should be designed so that it cannot be easily discarded. In order to reduce the possibility of it being discarded, it should be safe to
Interference of guards with various movements during operation of machinery and at other stages of the machine's life cycle is minimized.
Safety guards should.
a) The structure is sturdy and durable;
b) does not add any additional risk;
c) not easily bypassed or rendered inoperable;
d) There is a sufficient distance from the danger zone (see GB/T 23821 and GB/T 19876);
e) minimal visual barriers to observing the production process;
f) Only allow access to the area that has to be operated, and perform necessary work such as tool installation and/or replacement and maintenance, and as far as possible
Safety guards can be removed or rendered inoperative.
See 6.3.1~6.3.4 in GB/T 15706-2012 for general requirements of safety guards.
7.2.3.2 Supplementary protective measures
Depending on the intended use and reasonably foreseeable misuse of the machinery, safety upgrades may have to incorporate measures that are neither intrinsically safe, safety
Full protection, nor is it a supplementary protection measure for use of information. The following are some examples of supplementary protection measures.
--- Emergency stop device;
---Escape and rescue measures for trapped persons;
--- measures of isolation and energy dissipation;
--- Device for convenient and safe handling of heavy parts of machinery and equipment;
--- Measures for safe access to machinery and equipment.
See 6.3.5 in GB/T 15706-2012 for general requirements for supplementary protection measures.
7.2.4 Safety-related control systems
If the safety protection device used in the risk reduction measures needs to rely on the control system to achieve its safety function, it should be based on
Appendix A in GB/T 16855.1-2018 determines PLr. Safety-related control systems should be designed according to GB/T 16855.1-2018, and
Make sure that the performance level (PL) of the system satisfies PL≥PLr. If there is a class C standard and the corresponding PL value is specified, it should be in accordance with the specified
PL values are designed for safety-related control systems.
Not all components in the control system perform safety functions, such as some distance sensors, component counters or monitoring equipment, only the control
Safety-related components in the system belong to the scope of application of GB/T 16855.1-2018.For non-safety-related components in the control system,
There is no need to design according to GB/T 16855.1-2018.
In order to facilitate the determination of the PL value of the safety-related control system, when selecting the safety-related components of the control system, it is advisable to select the PL, DC,
Parts with related parameters such as PHFD, MTTFD or B10D.
7.2.5 Usage Information
For the residual risk after the risk reduction in accordance with 7.2.1~7.2.4, the user should be informed or warned in the form of usage information.
Security upgrades should include the drafting of usage information. The usage information shall meet the requirements of 6.4 in GB/T 15706-2012.
The usage information consists of text, words, signs, signals, symbols or diagrams, etc., and is presented to users (including special
professional and/or non-professional) to pass on information.
Where appropriate, this information should specify.
---Whether training is required;
---whether personal protective equipment is required;
---Whether it is necessary to take organizational measures such as safe work procedures, supervision, and work permit systems.
8 Security Upgrade Implementation
8.1 Overview
The implementation of safety upgrade should be based on the results of safety upgrade design, and the implementation of safety upgrade of mechanical equipment should be completed on site. During implementation, except
In order to carry out construction strictly in accordance with the safety upgrade design, measures should also be taken to ensure the safety of construction personnel and related personnel.
8.2 Qualifications
On-site construction personnel should understand the safety requirements of the construction site, and if necessary, the construction unit and/or personnel should also have corresponding qualifications.
8.3 On-site construction
During the construction project, the relevant safety production requirements shall be observed. At the same time, it is also suitable for operators, maintenance personnel, management personnel related to mechanical equipment.
Suppliers of personnel and/or machinery are fully communicated and coordinated to ensure that safety upgrades are implemented smoothly.
9 Security upgrade confirmation
9.1 Confirmation of safety precautions
It is advisable to confirm whether the safety protection measures adopted for the safety upgrade are in place through visual inspection and other methods.
9.2 Confirmation of safety functions
Measures should be taken to verify that the security safeguards adopted for security upgrades can achieve the intended security functions.
9.3 Validation of safety-related control systems
The components and safety circuits of safety-related control systems should be confirmed according to GB/T 16855.2.
9.4 Confirmation of residual risk
It should be confirmed by visual inspection and other methods whether texts, words, signs, signals, symbols are provided for the remaining risks after the safety upgrade.
or usage information such as charts.
9.5 Identification of new risks
Check whether the risk reduction measures taken by the security upgrade create new risks. If so, the security upgrade process in Chapter 4 should be followed
Deal with new risks.
9.6 Archive
Documentation related to security upgrades should be archived, including at least.
a) Security upgrade plan;
b) safety design drawings;
c) safety loop procedure;
d) safety product manual;
e) Calculation book for determining PL;
f) Safety upgrade confirmation acceptance list;
g) Usage Information.
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