Key safety standards all Controls Engineers must follow

Controls engineers are responsible for designing, implementing, and optimizing control systems that ensure the safe, efficient, and reliable operation of industrial equipment and processes. Given the complexity and potential hazards associated with control systems, it is essential for engineers to adhere to rigorous safety standards to protect both operators and equipment. In this article, we will explore the key safety standards that all controls engineers must follow to ensure the safety and performance of control systems in industrial environments.

1. ISO 13849: Safety of Machinery ? Safety-Related Parts of Control Systems

ISO 13849 is an international standard that provides guidelines for the design and integration of safety-related control systems in machinery. It focuses on ensuring that control systems used in machinery are safe, reliable, and capable of preventing hazards that could harm operators or other personnel. Key aspects of this standard include:

• Risk assessment and classification ? ISO 13849 requires controls engineers to assess potential risks and classify them based on their severity and probability. This helps determine the necessary level of safety measures needed in the control system.
• Functional safety requirements ? The standard outlines the functional safety requirements for control systems, including the need for redundancy, fault detection, and fail-safe mechanisms to ensure that the system continues to operate safely under all conditions.
• Performance levels (PL) ? ISO 13849 defines performance levels (PLr), which represent the reliability of a safety function. Controls engineers must ensure that the control system meets the required PLr based on the level of risk associated with the system.

By following ISO 13849, controls engineers can design and implement safety-related control systems that minimize risks and ensure the safety of workers in industrial environments.

2. IEC 61508: Functional Safety of Electrical, Electronic, and Programmable Electronic Systems

IEC 61508 is an international standard that outlines the requirements for the functional safety of electrical, electronic, and programmable electronic systems. This standard is widely used in industries like automotive, oil and gas, chemicals, and manufacturing, where control systems are critical for maintaining safe operations. Key aspects of IEC 61508 include:

• Functional safety lifecycle ? IEC 61508 defines a lifecycle approach to functional safety, covering everything from design and development to testing, installation, and maintenance. Controls engineers are required to follow this lifecycle to ensure that safety is maintained throughout the system's operational life.
• Safety Integrity Levels (SIL) ? IEC 61508 defines safety integrity levels (SIL), which represent the required level of safety for a control system. Engineers must determine the appropriate SIL based on the risk associated with the system and ensure that the system meets the necessary reliability and performance criteria.
• Redundancy and fault tolerance ? The standard emphasizes the need for redundancy and fault tolerance in safety-critical control systems. Controls engineers must design systems with backup components and fail-safe mechanisms to ensure continued safe operation in the event of a failure.

IEC 61508 is a fundamental standard for controls engineers working with safety-critical systems, helping to ensure that control systems are designed and operated with the highest levels of safety and reliability.

3. OSHA Regulations: Occupational Safety and Health Administration

In the United States, the Occupational Safety and Health Administration (OSHA) sets standards for workplace safety, including those related to control systems and automation. OSHA regulations ensure that control systems are designed and operated to prevent accidents, injuries, and fatalities in industrial environments. Key safety standards from OSHA include:

• Machine safeguarding ? OSHA requires that control systems for machinery include appropriate safeguards to protect workers from moving parts, electrical hazards, and other dangers. Controls engineers must design control systems that incorporate safety features such as emergency stop buttons, safety interlocks, and guarding systems.
• Lockout/tagout procedures ? OSHA mandates the implementation of lockout/tagout (LOTO) procedures to prevent accidental machine start-up during maintenance or repair activities. Controls engineers must design systems that enable LOTO procedures to be implemented safely and effectively, such as integrating emergency stop buttons and isolating power sources.
• Electrical safety standards ? OSHA also sets standards for electrical safety, including requirements for grounding, circuit protection, and wiring. Controls engineers must ensure that control systems comply with these electrical safety standards to prevent electrical hazards such as shocks, fires, or explosions.

By following OSHA regulations, controls engineers can design control systems that prioritize worker safety and prevent accidents in industrial environments.

4. NFPA 70E: Standard for Electrical Safety in the Workplace

The National Fire Protection Association (NFPA) 70E standard provides guidelines for electrical safety in the workplace, with a focus on preventing electrical accidents, injuries, and fires. Controls engineers working with electrical control systems must adhere to NFPA 70E standards to ensure the safety of personnel who operate and maintain electrical equipment. Key aspects of this standard include:

• Arc flash risk assessment ? NFPA 70E requires that an arc flash risk assessment be conducted to evaluate the potential hazards associated with electrical equipment. Controls engineers must use this assessment to design systems that minimize the risk of arc flash incidents and ensure proper protective measures are in place.
• Personal protective equipment (PPE) ? The standard outlines the requirements for personal protective equipment (PPE) for workers who interact with electrical systems. Controls engineers must design control systems with the understanding that operators may need to wear PPE, such as gloves, face shields, and arc-rated clothing, when working with electrical equipment.
• Safe work practices ? NFPA 70E provides guidelines for safe work practices when operating or maintaining electrical systems. Controls engineers must incorporate these practices into their designs to ensure that workers can perform tasks safely and with minimal risk of injury.

NFPA 70E is a critical standard for controls engineers working with electrical systems, ensuring that electrical hazards are minimized and that workers are protected from potential risks.

5. IEC 60204-1: Safety of Machinery ? Electrical Equipment of Machines

IEC 60204-1 is a standard that focuses on the electrical equipment of machines, providing guidelines for ensuring that electrical systems used in machinery are safe and reliable. This standard is essential for controls engineers who design electrical control systems for industrial machinery. Key aspects of IEC 60204-1 include:

• Electrical system design ? The standard outlines the requirements for designing electrical systems in machinery, including the proper selection of electrical components, wiring, grounding, and protection devices to ensure safety and compliance.
• Control panel design ? IEC 60204-1 provides guidelines for designing control panels that house electrical components such as switches, relays, and circuit breakers. Controls engineers must ensure that these panels are properly designed, labeled, and accessible to operators.
• Emergency stop systems ? The standard requires that machines be equipped with emergency stop systems that allow operators to quickly shut down equipment in the event of an emergency. Controls engineers must design control systems that include emergency stop buttons and safety interlocks to prevent accidents.

By following IEC 60204-1, controls engineers can ensure that the electrical control systems they design for machinery meet the highest standards of safety and reliability.

6. ISO 9001: Quality Management Systems

ISO 9001 is an international standard for quality management systems (QMS) that ensures products and services meet customer and regulatory requirements. Controls engineers working in manufacturing and automation must adhere to ISO 9001 standards to ensure that control systems are designed, developed, and maintained to the highest quality standards. Key aspects of ISO 9001 for controls engineers include:

• Documenting processes ? ISO 9001 requires that processes be clearly documented to ensure consistency and traceability. Controls engineers must maintain detailed records of their design processes, testing procedures, and maintenance activities to comply with ISO 9001.
• Continuous improvement ? The standard emphasizes the importance of continuous improvement in all processes. Controls engineers are encouraged to identify opportunities for improving control system design, performance, and safety, contributing to higher quality and better outcomes.
• Customer and regulatory compliance ? ISO 9001 ensures that control systems meet the needs of customers and comply with relevant regulatory requirements. Controls engineers must work closely with quality assurance teams to ensure that systems meet these standards.

By adhering to ISO 9001 standards, controls engineers help ensure that control systems are of the highest quality and meet customer and regulatory expectations.

Conclusion

Controls engineers are responsible for ensuring the safety, reliability, and performance of control systems in a wide range of industrial applications. Adhering to key safety standards, such as ISO 13849, IEC 61508, OSHA regulations, and NFPA 70E, is essential to protect workers, minimize risks, and ensure the proper functioning of control systems. By following these safety standards, controls engineers can design and implement control systems that contribute to safe, efficient, and reliable operations in industrial environments.