General Principles
Adaptation Cycle
This Regulatory Standard NR12 and its annexes define technical references, fundamental principles and protective measures to safeguard the health and physical integrity of workers and establishes minimum requirements for the prevention of accidents and illnesses at work in the design and use phases of machines and equipment, and also to its manufacture, import, commercialization, exhibition and assignment for any reason, in all economic activities, without prejudice to compliance with the provisions of the other NRs approved by Ordinance MTb no. 3,214, of June 8, 1978, in official technical standards or applicable international standards and, in the absence or omission of these, optionally, in harmonized European type “C” standards.
COMPLIANCE WITH NR12 STANDARD
Risk Assessment Report
Risk analysis and assessment is provided for in NR-12 and also in the technical standard NBR ISO 12100:2013, which deals with risk assessment by the Brazilian Association of Technical Standards (ABNT). This standard was developed to help designers, manufacturers and users interpret the essential safety requirements of machines. These principles are based on knowledge and experience of designs, use, incidents, accidents and risks associated with machines.
Risk analysis: is the specification of the machine's limits, identification of existing hazards and the estimation of associated risks. The report may indicate that the machine poses a negligible, low, high, very high, or unacceptable risk.
Risk assessment: When we talk about NR12, the categorization qualifies the danger in the equipment as a whole. It is through this tool that we will establish guidelines for the level of safety adequacy required for safety devices (sensors, actuators, controllers). The risk category of a machine is established in accordance with NBR 14153, which evaluates equipment safety systems. Thus, performance, in relation to the occurrence of defects in a part of a control system, is divided into five categories (B, 1, 2, 3 and 4).
Risk Appreciation: Risk Appreciation is provided for in NR12 as a way of diagnosing risks that may affect the safety of professionals who work with machines and equipment. It is provided for in the regulatory standard and can be diagnosed through the technical standard ABNT NBR ISO 12100:2013, which deals with risk appreciattion.
Mechanical Hazards
Hazards Associated with the Environment
Electrical Hazards
Combination of Hazards
Thermal Hazards
Hazards Linked to Vibration
Risk Categories Matrix
Risk Assessment Flowchart
Example of Report of Validation
ADEQUACY PROJECT
The safety project aims to reduce risks, or eliminate danger points identified in the risk assessment stage, through the detailed elaboration of the necessary control measures.This step is important and necessary before systems integration, as it can avoid subsequent costs, reduce failures and reduce machine downtime for adjustments.
Therefore, if risk reduction depends entirely on the functioning of the security system, it is important that it really is resistant to any type of defect. The parameters of the security systems are:
-
Reliability in relation to the performance of functionssecurity es;
-
Command system structure;
-
Quality of security-related documentation;
-
Specification quality;
-
Design, construction and maintenance;
-
Software quality and accuracy;
-
Range of functional tests;
-
Operating characteristics of the machines or part of the machines under command.
Phases of a Security Project
The security project consists of the following phases:
-
Specification of security requirements;
-
Classification of security requirements;
-
Definition of security integrity levels and performance levels;
-
Specification of the most appropriate safety equipment;
-
Preparation of detailed mechanical design for the construction of protections;
-
Preparation of electrical, pneumatic and hydraulic installation diagrams
Bill of Materials
Stages of a Machinery Safety project.
Firstly, in order to carry out machine safety design, hazard analysis and risk assessment must be carried out. Initially, it is necessary to identify risks in all forms of machine operation and stages of its life. Then, it must be evaluated in order to decide which are the best alternatives to reduce this risk. After this, it is necessary to decide on measures to reduce risk. Therefore, design measures or the application of protections to reduce risk must be defined. After carrying out this procedure, it is necessary to specify the protection requirements.
Therefore, in this step, you must specify the safety functions of the control system. Each part must have its category and it is also necessary to identify how safety must be achieved. After this, the parts of the control system must be designed according to the specifications mentioned above. Therefore, the aspects that served as the logical basis of the project will be listed according to their respective categories. All functions and safety categories that were achieved in the project, after specification, will be validated and redesigned, if necessary.
Machine safety design has a very high level of importance in order to guarantee physical integrity. Mainly when it comes to operating machines, which is very dangerous. Therefore, always check new standards determined by the Ministry of Labor, this way you can guarantee everyone's integrity. Therefore, you must do so carefully and following all the parameters required by your specific regulatory standard. Likewise, with other standards that complement some steps. So, now you know how to carry out a machine safety project, so do it now!
Bill of Materials.
A very important item in the preparation of an executive NR12 adaptation project, the list of materials must contain in detail all the materials to be used in the adaptation of each machine individually. These items must be described with all relevant technical specifications, part numbers, manufacturers, estimated price, guarantees,production/delivery time,etc... The financial control of the project reported through the costs of materials and services is decisive in the success or failure of the implementation, since such resources must be determined during the execution of the project with the definition of the lists of materials and services.
IMPLEMENTATION
We have reached the stage of implementing the adjustments. All information obtained through Risk Analysis, Risk Assessment and Risk Assessment resulted in the preparation of adaptation projects (Mechanical, Electrical, Hydraulic and Pneumatic). From the projects resulting from the analysis, Material Lists and Descriptive Memorandums of adaptation procedures for each machine will be obtained.. Just remembering that disassembly/assembly, removal and transportation are pertinent activities that must be observed and considered in the Risk Analysis. It is also worth highlighting the importance of faithful complianceof all Project guidelines, since after carrying out the Implementation, the next step is to Validate the Adequacies for preparing the Validation Report.
Adequação NR12
Adequação NR12
Guarda Corpo
Adequação NR12
VALIDATION REPORT
OValidation ReportorCompliance Report, is the document produced after the Risk Assessment, Design and Implementation stages. The dangers and risks found in the assessment stage will serve as parameters for the preparation of Mechanical and Electrical projects that aim to mitigate the risks identified through the methodHRN (Hazard Rating Number)which is today the most used to define the degree of risk of a machine or equipment. Validation or Conformity Reports are considered legal documents and must be accompanied by the respective ART's (Technical Responsibility Note) that indicate the technical person responsible for the service or work performed. ART's must be issued by Engineers or Architects registered in the CONFEA/CREA systems.
Hazard Rating Number - HRN = (LO x FE x DPH x NP)
*LO = Probabilidade de Ocorrência
*FE = Frequência de Exposição ao Risco
*DPH = Grau de Severidade do Dano
*NP = Número de Pessoas Expostas ao Risco
Validation or Compliance Report will demonstrate, machine by machine, the values obtained in the Risk Assessment and the respective individual results, after carrying out the adjustments defined in the Mechanical and Electrical Projects.
