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This seminar provides a practical method of assessing system requirements, designing a control reliable system, and selecting the appropriate components.

Course Outline
To provide safety for personnel, many manufacturing processes in Ontario require the application of control reliable safety systems for automated machine guarding. This seminar provides a practical method of assessing system requirements, designing a control reliable system, and selecting the appropriate components. This seminar also provides guidance to ensure that systems meet the requirements of a Pre-Start Health and Safety review by meeting applicable standards. The course is taught by experts with a broad range of hazardous materials management experience.

Objective To develop a understanding of the regulatory issues surrounding the design of control reliable safety systems and to provide a practical guideline for the general design of control reliable systems used for interlocked machine guarding.

Who Should Attend Machine designers who design production equipment, process integrators, engineers and technicians responsible for equipment and facility safety, purchasers of equipment, maintenance personnel responsible for maintaining or modifying equipment, and plant or production managers wishing to ensure compliance with applicable legislation and a reduction of risk for machine safety.

Program Outline
1)   Introduction

• Introduction of Instructor
• Course Outline: designed for Ontario manufacturing sector
• Objectives (knowledge of applicable legislation and Standards, approach to hazard and  risk assessment, selection of components, general design of systems, selection of proper components) 
• Includes automatic safeguarding systems- electronic, hydraulic, pneumatic, mechanical

2)   Theory of Control Reliability
• General approach to safety
• General approach to machine guarding (isolation, point of operation guarding)
• Concept of redundancy (application)
• Concept of fail safe (control failures, common mode failures)
• Monitoring requirements (manual, automatic, interlocking)
• Development of technology (PLC, statistical process control)
• Development of standards (Europe vs. North America, Canada vs U.S.)

3)   Legal Requirements for Control Reliable Systems In Ontario
• Occupational Health and Safety Act
• O. Reg 851 Regulation for Industrial Establishments
• Guarding vs. interlocks (fixed guarding, interlocking, allowances)
• Interlocks vs. lockout (stored energy, production vs maintenance)
• Emergency stops (application, single circuit)
• Due diligence
4)   Standards- Part 1
• Origin of European standards: Directive 98/37/EC
• EN 954-1 (1997)
• ISO 14121
• The CSA series (Z142-02, , Z-434-03, Z 432-04)
• Other CSA standards ( Z 321-96, Z431-02, Z-460-05)
• ANSI standards (B-Series)
• Other European standards  (EC 13849, harmonized EN standards)
5)   Standards - Part 2
• Choosing the right standard (hierarchy, overlap, partial application)
• Hazard assessment (limits, machine use, observation)
• Risk assessment (qualitative vs. quantitative, parameters, CSA vs. EN)
• Alternatives to standards
6)   General Design Approach
• Appling the hazard assessment
• Production zones
• Applying the risk assessment
• Use of fixed guarding
• Stopping times
7)   Actuators/Sensors
• Single beams (sensors, object sensitivity, response times, evaluation)
• Multiple beams/ area scanners (limitations, evaluation)
• Switches (contacts, evaluation)
• Other devices (RFID, magnets, sonar)
• Common problems and issues
8)   Circuits
• Redundant circuits (maintaining redundancy, Category 3 and 4)
• Common relays (electromechanical vs. electronic, AC vs DC)
• Safety relays (features, limits)
• Safety PLCs (features, limits, process vs. safety)
• Monitoring (types, interlocking)
• Hydraulic circuits (control vs. process)
• Pneumatic circuits (control vs. process)
• Common problems
9)   Stopping Devices
• Electrical power stoppage (speed, power)
• Contacts and switches (reliability, design)
• Pneumatic valves (closure, pilot operation, solenoid, ratings)
• Hydraulic valves (closure, pilot operation, solenoid, ratings)
• Brakes (speed, power)
• Other devices (blocks, delayed response)
10) Integrating the Design
• Pre-Start Health and Safety Review (application, exemptions)
• Documentation (components, system integration, drawings)
• Testing (circuits, frequency)
• Training (operation, maintenance)
• Signage (operational controls, zones)
• Record keeping (training, repairs, testing)
11) Case Studies and Examples
• Hydraulic brake presses (operational issues, light curtain placement, Rams blocks- case study)
• Pneumatic punch presses (operational issues, system components, Response time- case study)
• Robotic cells (operational issues, servo motors, category 4, case study)
• Mechanical grinders and shredders (residual motion, cleaning- case study)

12) Workshop and Open Questions
• Workshop (from class provided Case Study)
• Questions
There will be a one hour lunch break each day in addition to a refreshment and networking break during each morning and afternoon session.
After Participating in this Course, You will be Able to:
  • identify machine guarding applications requiring control reliable systems
  • identify the appropriate standards to apply complete risk assessments
  • evaluate systems for compliance
  • select equipment and components
  • design simple safety control circuits.
Daily Schedule:
8:00        Registration and coffee (1st day only)
8:30        Session begins
12:00      Lunch
4:30        Adjournment
Prerequisites & Certificates

Certificates offered

0.6 CEUs / 6 PDHs

Cancellation Policy
To withdraw from a course, you must send a request, in writing, with the official receipt to our office. Fifteen or more business days in advance: full refund less $50.00 administration charge. Five to fifteen business days in advance: non-refundable credit of equal value for any future EPIC seminar within one year. Credits are transferable within your organization. In case of an unexpected event occurring after this time, you may send someone else to take your place without any additional cost.
Map & Reviews
EPIC Educational Program Innovations Center
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Here are some reviews of the training vendor.
The course was very well presented and the course instructor was absolutely amazing.
Reviewed by 2013
Our instructor, Stephen Lamming, was outstanding and a true expert in his field. He was able to complement the technical air monitoring information with practical real life examples which was highly beneficial. He is an excellent communicator and was highly interactive with the course attendees. This course was recommended to me because Stephen Lamming does an outstanding job. I was very impressed with this course and have subsequently recommended it to my colleagues.
Reviewed by 2012
Would have liked more interactive problem solving.
Reviewed by 2011

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