Emerson EL-O-Matic F-Series Benutzerhandbuch

SIL Safety Manual

DOC.SILM.EF.EN Rev. 1

September 2018

EL-O-Matic F-Series

SIL Safety Manual

EL MaticTM

SIL Safety Manual

DOC.SILM.EF.EN Rev. 1

Table of Contents

September 2018

ITable of Contents

Table of Contents

Section 1: Introduction

Section 2: Functional Specification

Section 3: Configuration of the Product

Section 4: Service Condition Limitations (Limitation of Use)

Section 5: Expected Lifetime

Section 6: Failure Modes and Estimated Failure Rates

Section 7: Installation and Site Acceptance Procedure

Section 8: Periodic Test and Maintenance Requirements

8.1 General...................................................................................................... 9

8.2 Full-Stroke Test .......................................................................................... 9

8.3 Partial-Stroke Test.................................................................................... 12

8.4 Proof Test and Periodic Maintenance........................................................ 15

Section 9: Architectural Constraints

Section 10: Common Cause Factors

Section 11: Mean Repair Time

Section 12: Systematic Capability

September 2018

SIL Safety Manual

DOC.SILM.EF.EN Rev. 1

Introduction

Section 1: Introduction

Purpose of this Safety Manual, written in compliance with IEC 61508-2, Annex D, is to give

all the necessary information to the system integrator for a correct use of the product in

Safety Instrumented Systems for SIL classied applications.

Section 1: Introduction

SIL Safety Manual

DOC.SILM.EF.EN Rev. 1

September 2018

Functional Specication

Section 2: Functional Specication

The safety function for El-O-Matic F-Series pneumatic actuator is dened as follows:

Double-Acting Scenario:

a. When an unsafe condition is detected in a plant by a process sensor, the

controller, via actuator control system, drives the Actuator to close the

shut-down valve, depressurizing (if under pressure) the Opening side of

the actuator and pressurizing the Closing side of the actuator.

b. When an unsafe condition is detected in a plant by a process sensor, the

controller, via actuator control system drives the Actuator to open the

blow-down valve, depressurizing (if under pressure ) the Closing side

of the pneumatic actuator and pressurizing the Opening side of the

pneumatic actuator.

Single-Acting Scenario:

a. When an unsafe condition is detected in a plant by a process sensor, the

controller, via actuator control system drives the Actuator to rotate with

sufcient torque to move a valve to its fail-safe state when hold-position

air pressure is released.

The El-O-Matic brand Actuator Selection Procedure provides functional denition with

specics on input variables and performance.

In any case, the choice of the safety function to be implemented is responsibility of the

system integrator.

Section 2: Functional Specification

September 2018

SIL Safety Manual

DOC.SILM.EF.EN Rev. 1

Conguration of the product

Section 3: Conguration of the Product

The El-O-Matic F-Series are pneumatically operated actuators designed to operate Ball /

Plug / Buttery valves, automation of louvers and dampers & automation of any

quarter-turn mechanism. Both the double-acting and single-acting (spring-return) versions

of the El-O-Matic F-Series pneumatic actuators are designed in such a way that there are

no moving parts on the outside (with the exception of the position indicator). This makes

them safe, easy to install and virtually maintenance free.

For further details about actuator congurations, please refer to the El-O-Matic F-Series

product data sheets, Safety guide and Installation, Operation and Maintenance manual.

Section 3: Configuration of the product

SIL Safety Manual

DOC.SILM.EF.EN Rev. 1

September 2018

Service Condition Limitations (Limitation of Use)

Section 4: Service Condition Limitations

(Limitation of Use)

The operating capabilities are listed below:

• Maximum Operating Pressure:

– Pneumatic Service

– Up to 120 psig (8.3 barg)

• Ambient Temperature:

Temperature extremes require different solutions to maintain actuator operational

integrity and reliability. For each El-O-Matic F-Series actuator is available in three

different temperature executions.

– -20°C to +80°C (-4°F to +176°F) Standard temperature

– -10°C to +120°C (+14°F to +250°F) High Temperature

– -40°C to +80°C (-40°F to +176°F) Low Temperature

• Torque Output Range:

– Double-Acting El-O-Matic F-Series actuators, requiring pressure to rotate

in either direction, are available with a torque range between 4.8 Nm

(44 lbf.in) and 6,490 Nm (59000 lbf.in)

– The El-O-Matic F-Series spring-return models require pressure in only one

direction of travel and are suitable for air-fail close and air-fail to open

applications without modication. These models are available with a

spring end torque between 2 Nm (20 lbf.in) and 2394 Nm (21000 lbf.in)

• Safety Function:

For spring-return models, the safety function is self-evident performed by the

springs. The safety function of double-acting models should be performed by the

A-chamber for safety related systems.

Figure 1 Use the A-Chamber for Safety Related Systems on Double-Acting Actuators

Assembly Code: CW Assembly Code: CC

= Safety Function is = Safety Function is

Counterclockwise Rotation Clockwise Rotation

PistonsPistons

Pinion

Section 4: Service Condition Limitations (Limitation of Use)

September 2018

SIL Safety Manual

DOC.SILM.EF.EN Rev. 1

Service Condition Limitations (Limitation of Use)

• Use of manual override:

The use of a manual override is not recommended in a SIL classied application, as

it results in a bypass of the safety function. In case the manual override is used, the

following requirements must be fullled, or the Functional Safety Certication will

become invalid:

– The manual override shall be protected to prevent unauthorized use.

(e.g. by key locks in conjunction with effective management controls.).

– The users authorized to operate on the actuator shall be skilled personnel;

– The maximum duration of the manual override shall be dened.

– If necessary, compensatory measures to allow the safe operation of the

process shall be dened (responsibility of the nal user).

• When test or bypass facilities are included in the SIS (safety integrated system),

they shall conform with the following:

– The SIS shall be designed in accordance with the maintenance and testing

requirements dened in the SRS (safety requirement specication).

– The operator shall be alerted to the bypass of any portion of the SIS via an

alarm or operating procedure.

Before selecting remote operating mode control of actuator, the manual override must be

disengaged according to the relevant Installation, Operation and Maintenance Manual.

The position selected (remote/automatic control or local /manual control) can be achieved

with a specic technical solution that does not allow to reach an intermediate position

lever’s and avoids unintentional activation.

The engagement of the manual override shall be signaled, at least locally, according to

IOM. As optional request from nal user, to determine if the manual override is engaged, an

electrical signal using contact switching can be provided to communicate the status to the

control room.

• Loss of utility:

For double acting congurations that on loss of utility (e.g., electrical power,

or pneumatic supply) does not fail to the safe state a system for detecting and

alarming of loss of utility and SIS circuit integrity shall be implemented. (e.g., end-

of-line monitoring, supply pressure measurement), and action taken according to

par. 11.3 of IEC. 61511-1.

Section 4: Service Condition Limitations (Limitation of Use)

SIL Safety Manual

DOC.SILM.EF.EN Rev. 1

September 2018

Expected Lifetime

Section 5: Expected Lifetime

Actuator lifetime (for which failure rates indicated in Section 6 are ensured) strongly

depends on operating conditions.

For normal service conditions, EL-O-Matic F-Series actuators can be in good conditions

also after more than 10 years with planned minimum maintenance. Normal working life is

500.000 cycles. El-O-Matic F-Series carry a warranty period of:

• 18 months after delivery if properly stored in conditions that we declare or

• 12 months after installation on site.

Section 5: Expected Lifetime

September 2018

SIL Safety Manual

DOC.SILM.EF.EN Rev. 1

Failure Modes and Estimated Failure Rates

Section 6: Failure Modes and Estimated

Failure Rates

Table 1. Failure Modes and Estimated Failure Rates – El-O-Matic F-Series Actuator

Configuration Safety Function λDU [1/h] λDD [1/h] λS [1/h]

F- No PST 1 2,55E-08 0,00E+00 0,00E+00

F - With PST 1 2,29E-09 2,.32E-08 0,00E+00

NOTE:

• No internal diagnostics is included in the product.

• The above failure rates are guaranteed:

- For the service conditions listed in Section 4.

- For the expected lifetime declared in Section 5.

- Considering the periodic test and maintenance included in Section 8.

The failure rates are determined performing a FMEDA based on the failure rates of

components taken from industrial databases (NPRD-2016/FMD97/2016, EXIDA E&MCRH

and NSWC-2011), integrated with eld feedback using the Bayesian statistical approach

mentioned in IEC 61508-2 Par. 7.4.4.3.3.

The system for reporting failures is based on eld feedback from end users, with:

- Identication of the claim/failure

- Root cause analysis to identify cause and responsibility of the failure

- Identication of the possible effect of the failure on the Safety Function

- Classication of the failure considering the failure categories of IEC 61508-2

(Safe, Dangerous, No Effect) Customer Service, Quality and Technical

Department are responsible for the procedure, according to the respective role.

Section 6: Failure Modes and Estimated Failure Rates

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