BS PD 5304-2014 Guidance on safe use of machinery《机械设备安全使用指南》.pdf

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1、BSI Standards Publication Guidance on safe use of machinery PD 5304:2014 This publication is not to be regarded as a British StandardPD 5304:2014 Publishing and copyright information The BSI copyright notice displayed in this document indicates when the document was last issued. The British Standard

2、s Institution 2014 Published by BSI Standards Limited 2014 ISBN 978 0 580 81885 1 ICS 13.110 The following BSI references relate to the work on this document: Committee reference MCE/3 Draft for comment 14/30303313 DC Publication history First published as CP 3004, March 1964 First revision as BS 53

3、04, December 1975 Second revision March 1988 First published as PD 5304, July 2000 Second edition, December 2005 Third (present) edition, December 2014 Amendments issued since publication Date Text affected The British Standards Institution 2014 i PD 5304:2014Committee responsible for this Published

4、 Document The preparation of this Published Document was entrusted to Technical Committee MCE/3, upon which the following bodies were represented. Agricultural Engineers Association Association of Manufacturers of Power Generating Systems British Cables Association British Compressed Air Society Bri

5、tish Fluid Power Association Department for Business, Innovation and Skills Food and Drink Federation GAMBICA Association Ltd Health and Safety Executive Institute of Measurement and Control Manufacturing Technologies Association Safety Assessment Federation LimitedPD 5304:2014 ii The British Standa

6、rds Institution 2014 This page deliberately left blank The British Standards Institution 2014 iii PD 5304:2014Contents Introduction by Dave Bench viii Foreword ix Section 1: General 1 1.1 Scope 1 1.2 Normative references 1 1.3 Terms and definitions 2 Section 2: Strategy for selecting protective meas

7、ures 5 2.1 General 5 2.2 Selection of protective measures 6 2.3 Avoidance of reasonably foreseeable misuse of guards and protective devices 7 2.4 Phases of machine life 7 Section 3: Risk assessment 9 3.1 General 9 3.2 Severity of harm 11 3.3 Probability of occurrence of harm 11 3.4 Risk evaluation 1

8、1 3.5 Documentation 12 Section 4: Identification of hazards 13 4.1 Hazards at machinery 13 4.2 Mechanical hazards 14 4.3 Nonmechanical hazards 28 Section 5: Aspects of machine design to eliminate or reduce risks 33 5.1 Design for safe use 33 5.2 Checks by user 33 5.3 Further considerations for safeg

9、uards 34 5.4 Controls 34 5.5 Indicators 37 5.6 Unexpected/unintended startup 37 5.7 Measures for the escape and rescue of trapped persons 38 5.8 Clutches 38 5.9 Braking systems 39 5.10 Safety catches, overrun, runback and fallback protection devices 41 5.11 Counterweights and similar devices 41 5.12

10、 Rotating shafts, spindles and couplings 41 5.13 Feeding and takeoff devices 43 5.14 Hydraulic and pneumatic systems 43 5.15 Electrical systems 43 5.16 Workholding devices 43 5.17 Lifting, handling and transport 44 5.18 Static and dynamic stability 44 5.19 Lubrication 45 5.20 Lighting 45 5.21 Hygien

11、e and guard design 45 5.22 Safety markings, signs (pictograms) and written warnings 45 5.23 Access (see also Section 11) 46 5.24 Programmable systems 46 Section 6: Selection of safeguards 49 6.1 General 49 6.2 Where access to the hazard zone is not required during normal operation 51 6.3 Where acces

12、s to the hazardous area can be required during normal operation 52 6.4 Where access to the hazard zone is required during normal operation 52 6.5 Access to the hazardous area for infrequent operation 52PD 5304:2014 iv The British Standards Institution 2014 Section 7: Guard design and construction 53

13、 7.1 General 53 7.2 Types of guard 53 7.3 Guard construction 76 7.4 Anthropometric considerations 80 Section 8: Protective devices 81 8.1 Trip devices (see Figure 56 to Figure 61) 81 8.2 Pressuresensitive cables (see Figure 67) 91 8.3 Holdtorun control 93 8.4 Enabling device 93 8.5 Twohand control d

14、evice (see Figure 68) 93 8.6 Limiting and limited movement control devices 94 8.7 Mechanical restraint device (see Figure 69 and Figure 70) 95 8.8 Emergency operation emergency stop and emergency switching off 97 Section 9: Interlocking 103 9.1 Functions of an interlock 103 9.2 Interlocking media 10

15、3 9.3 Interlocking methods for power interruption 103 9.4 Interlocking methods incorporating braking, purging, etc., and/or guard locking 105 9.5 Security of interlocking 106 9.6 Electrical interlocking devices 109 9.7 Mechanical interlocking devices 126 9.8 Pneumatic interlocking devices 128 9.9 Hy

16、draulic interlocking devices 132 Section 10: Safetyrelated control systems associated with protective devices 135 10.1 General 135 10.2 Architectural considerations 135 10.3 Safetyrelated control systems 158 Section 11: Installation considerations 159 11.1 Layout of machinery and plant 159 11.2 Movi

17、ng parts of machinery 159 11.3 Services 159 Section 12: Maintenance and safe working practices 161 12.1 General 161 12.2 Maintenance 161 12.3 Safe working practices 162 12.4 Supervisory control 167 12.5 Information and training 168 Annexes Annex A (normative) Ergonomic data 171 Annex B (informative)

18、 Common types of failures associated with safetyrelated interlocking control systems 179 Annex C (informative) Essentials of a permit to work form 187 Bibliography 189 List of figures Figure 1 Enclosed tools at a power press 5 Figure 2 Iterative process to reduce risk 10 Figure 3 Individual parts of

19、 machines causing one or more types of injury, e.g. hazards at an abrasive wheel 14 Figure 4 Entanglement caused by contact with a single rotating surface 15 Figure 5 Entanglement caused by catching on projections or in gaps 16 Figure 6 Drawingin hazards between two counterrotating parts 16 Figure 7

20、 Entanglement caused by catching between rotating and other moving parts 16 Figure 8 Entanglement caused by catching between rotating and fixed parts 18 The British Standards Institution 2014 v PD 5304:2014 Figure 9 Entanglement caused by catching in materials in motion (swarf) 18 Figure 10 Friction

21、 and abrasion hazards 19 Figure 11 Cutting hazards 20 Figure 12 Shear hazards between two machine parts 21 Figure 13 Shear hazards between a machinery part and a workpiece 22 Figure 14 Removal of shear trap by design 22 Figure 15 Gap cover to prevent shear trap 23 Figure 16 Stabbing and puncture by

22、flying objects 24 Figure 17 Stabbing and puncture by rapidly moving parts of machinery or pieces of material 24 Figure 18 Impact hazards 25 Figure 19 Crushing hazards 26 Figure 20 Drawingin hazards between rotating and tangentially moving surfaces 27 Figure 21 Roller conveyor: first idle roller free

23、 to prevent drawingin 28 Figure 22 Foot pedal protected from accidental operation by means of a cover 35 Figure 23 Guarding of shafts and couplings: Fixed guard for a transmission shaft and coupling 42 Figure 24 Tractor power takeoff drives 42 Figure 25 Telescopic type guard 43 Figure 26 Fundamental

24、 considerations involved in guarding a machine 49 Figure 27 Fixed enclosing guard constructed of wire mesh and angle section preventing access to transmission machinery from all directions 54 Figure 28 Fixed guards for chains and chain wheels 55 Figure 29 Example of a quick release fixed guard 56 Fi

25、gure 30 Use of flat plate or angle section to prevent access to inrunning nips 56 Figure 31 Feeding material to a pair of rollers 57 Figure 32 Small horizontal table, stiffened to prevent deflection, spanning the full width of a calender 57 Figure 33 Use of fixed curve metal plates to prevent access

26、 to inrunning nips 58 Figure 34 Fixed guard that allows continuous observation of the inrunning nip point 58 Figure 35 Captive drawer 59 Figure 36 Feeding of bulk material from the floor above the machine 60 Figure 37 Transparent tunnel guard with conveyor belt 61 Figure 38 Example of interlocked tu

27、nnel guard 61 Figure 39 Example of interlocking tunnel guard on food preparation machinery 62 Figure 40 Fixed distance guard fitted to a press brake 63 Figure 41 Example of guarding an industrial robot with a perimeter fence type guard 64 Figure 42 Close contour perimeter fence guard 64 Figure 43 Po

28、weroperated guards and doors 66 Figure 44 Balance weights to reduce the effort required to open a rise and fall guard 67 Figure 45 Latch (restraint) to protect against gravity fall of an airoperated guard which has no balance weight 67 Figure 46 Sensing guard fitted to a riveting gun 69 Figure 47 Ex

29、ample of interlock on a hopper extension 70 Figure 48 Adjustable guard for a radial or pedestal drilling machine 72 Figure 49 Adjustable guard on a circular sawing machine 73 Figure 50 Adjustable guard for the cutters of horizontal milling machines 73 Figure 51 Selfadjusting guard arrangements for s

30、nipper crosscut sawing machine 74 Figure 52 False table and fixed guard applied to a milling machine 75 Figure 53 False table and interlocking guard applied to a rotating table pie and tart machine 76PD 5304:2014 vi The British Standards Institution 2014 Figure 54 Support for a horizontally sliding

31、guard 79 Figure 55 Opening in a fixed guard at a metal cutting guillotine 80 Figure 56 Distance bar trip guard 82 Figure 57 Trip device on a flat work ironing machine (calender) used in laundries 83 Figure 58 Trip device for horizontal tworoll mills used in the rubber industry 84 Figure 59 Trip devi

32、ce that protects against the hazards associated with goods on a conveyor passing into wrapping machinery 84 Figure 60 Trip bar for mitigating the risk of trapping between a downrunning conveyor and the casing of a final prover 85 Figure 61 Trip device for drilling machines 86 Figure 62 Electrosensit

33、ive protective equipment using light curtains (AOPDs) as a trip and presencesensing device at a press brake 87 Figure 63 Electrosensitive protective equipment using light curtains (AOPDs) as a trip device at a depalletizer 88 Figure 64 Electrosensitive protective equipment using light curtains (AOPD

34、s) as presencesensing devices at a robotserved pressure die casting machine 88 Figure 65 Electrosensitive protective equipment equipped with active optoelectronic devices responsive to diffuse reflection (AOPDDRs) used as trip and presencesensing devices on an automated guided vehicle (AGV) 89 Figur

35、e 66 Pressuresensitive mat safeguarding the clamping and bending jaws of an automatic horizontal tube bender 91 Figure 67 A typical pressuresensitive cable installation used as a trip device 92 Figure 68 Twohand control device 94 Figure 69 Augmenting an interlocking guard with a mechanical restraint

36、 device 96 Figure 70 Mechanical restraint 97 Figure 71 Emergency stop button 98 Figure 72 Emergency stopping of conveyors 100 Figure 73 Defeatability of sliding interlocking guards 107 Figure 74 Defeatability of hinged interlocking guards 108 Figure 75 Mounting of individual position switches 111 Fi

37、gure 76 Position switches or valves actuated by rotary cams 112 Figure 77 Actuation of rolleroperated position switches or valves by a cam 112 Figure 78 Position switches actuated by rotary cams (guard in open position) 113 Figure 79 Large hinged guards 113 Figure 80 Position switch operating in the

38、 nonpositive mode (incorrect application) 114 Figure 81 Two position switches operating in opposite modes, mounted sidebyside, each actuated by its own cam mounted on the guard hinge 114 Figure 82 Mounting of position switches in opposite modes 115 Figure 83 Solenoid locking interlock switch 116 Fig

39、ure 84 Captivekey switch 117 Figure 85 Time delay captivekey unit 117 Figure 86 Trappedkey interlocking systems 118 Figure 87 Practical application of the trappedkey interlocking system shown diagrammatically in Figure 86a) 119 Figure 88 Internal mixing machine: example of the use of a trappedkey in

40、terlocking system 120 Figure 89 Example use of a noncontact switch where an interlocking guard has to be removed 122 Figure 90 Manuallyoperated delay device 124 Figure 91 Locking a guard closed with a shotbolt 125 Figure 92 Guard locking power interlocking 126 Figure 93 Interlocking guard for positi

41、ve clutch power press 127 Figure 94 Principles of mechanical interlocking 128 Figure 95 Diagrams for a camoperated pneumatic interlocking valve 130 The British Standards Institution 2014 vii PD 5304:2014 Figure 96 Interlocking guard with and without guard locking 131 Figure 97 Power interlocking in

42、hydraulic systems 134 Figure 98 Designated architecture 136 Figure 99 Prevention of earth fault sneak circuits 140 Figure 100 Example of singlecontrol system interlocking 141 Figure 101 Singlecontrol system interlocking for arresting the motion of a cylinder 144 Figure 102 Dualcontrol system interlo

43、cking without crossmonitoring: both channels pneumatic 145 Figure 103 Principles of pneumatic and electrical circuits: dualcontrol system interlocking with crossmonitoring, one control channel pneumatic, one electric (monitoring channel electric) 146 Figure 104 Use of an equalizing valve 149 Figure

44、105 Control interlocking for machinery performing functions in sequence 150 Figure 106 Locking a guard closed (see also 9.4.3) 151 Figure 107 Singlecontrol system interlocking used to interrupt the main hydraulic supply to the actuator 152 Figure 108 Dualcontrol system interlocking without crossmoni

45、toring 153 Figure 109 Dualcontrol system interlocking with crossmonitoring 154 Figure 110 Hydraulic press: control of stroke 156 Figure 111 Rapid closing of an upstroking press 157 Figure 112 Multipadlockable hasp 165 Figure 113 Example of padlock complete with danger board for lockingoff after isol

46、ation 165 Figure 114 Gravity or springoperated latch 166 Figure A.1 Safety distance for reaching upwards 172 Figure A.2 Diagram showing dimensions a, b and c used in Table A.1 and Table A.2 173 Figure A.3 Safety distances for openings of irregular shape 178 Figure C.1 Example of a permit to work for

47、m 187 List of tables Table A.1 Low risk values of a, b and c for Figure A.2 174 Table A.2 High risk values of a, b and c for Figure A.2 175 Table A.3 Safety distances 176 Table A.4 Safety distances, s r, through regular openings of size e 177 Summary of pages This document comprises a front cover, a

48、n inside front cover, pages i to x, pages 1 to 192, an inside back cover and a back cover.PD 5304:2014 viii The British Standards Institution 2014Introduction by Dave BenchHealth and Safety Executive Director of Science The Health and Safety Executive (HSE) welcomes the publication by the British Standards Institution of PD 5304:2014, which was developed by Technical Committee MCE/3, Safeguarding of machinery, with contributions and support from HSE. PD 5304:2014 covers the safe use of machinery and provides comprehensive guidance on practical measures a