Fisher A41 Konfigurationshandbuch

www.Fisher.com

Safety manual for Fisher™A41 Valve

Purpose

This safety manual provides information necessary to design, install, verify and maintain a Safety Instrumented

Function (SIF) utilizing the Fisher A41 valve.

WARNING

This instruction manual supplement is not intended to be used as a stand-alone document. It must be used in conjunction

with the following manual: Fisher A41 High Performance Butterfly Valve Instruction Manual (D500211X012)

Failure to use this instruction manual supplement in conjunction with the above referenced manual could result in personal

injury or property damage. If you have any questions regarding these instructions or need assistance in obtaining any of

these documents, contact your Emerson sales office or Local Business Partner.

Introduction

This manual provides necessary requirements for meeting the IEC 61508 or IEC 61511 functional safety standards.

Figure 1. Fisher A41 Valve

W9269

A41 Valve

June 2017

Instruction Manual Supplement

D103546X012

Instruction Manual Supplement

D103546X012

A41 Valve

June 2017

Terms and Abbreviations

Safety: Freedom from unacceptable risk of harm.

Functional Safety: The ability of a system to carry out the actions necessary to achieve or to maintain a defined safe

state for the equipment / machinery / plant / apparatus under control of the system.

Basic Safety: The equipment must be designed and manufactured such that it protects against risk of damage to

persons by electrical shock and other hazards and against resulting fire and explosion. The protection must be

effective under all conditions of the nominal operation and under single fault condition.

Safety Assessment: The investigation to arrive at a judgment  based on the facts  of the safety achieved by

safetyrelated systems.

FailSafe State: State where valve actuator is deenergized and spring is extended.

Fail Safe: Failure that causes the valve to go to the defined failsafe state without a demand from the process.

Fail Dangerous: Failure that does not respond to a demand from the process (i.e. being unable to go to the defined

failsafe state).

Fail Dangerous Undetected: Failure that is dangerous and that is not being diagnosed by automatic stroke testing.

Fail Dangerous Detected: Failure that is dangerous but is detected by automatic stroke testing.

Fail Annunciation Undetected: Failure that does not cause a false trip or prevent the safety function but does cause

loss of an automatic diagnostic and is not detected by another diagnostic.

Fail Annunciation Detected: Failure that does not cause a false trip or prevent the safety function but does cause loss of

an automatic diagnostic or false diagnostic indication.

Fail No Effect: Failure of a component that is part of the safety function but that has no effect on the safety function.

Low Demand Mode: Mode, where the frequency of demands for operation made on a safetyrelated system is no

greater than twice the proof test frequency.

Acronyms

FMEDA: Failure Modes, Effects and Diagnostic Analysis

HFT: Hardware Fault Tolerance

MOC: Management of Change. These are specific procedures often done when performing any work activities in

compliance with government regulatory authorities.

PFDAVG:Average Probability of Failure on Demand

SFF: Safe Failure Fraction, the fraction of the overall failure rate of a device that results in either a safe fault or a

diagnosed unsafe fault.

SIF: Safety Instrumented Function, a set of equipment intended to reduce the risk due to a specific hazard (a safety

loop).

SIL: Safety Integrity Level, discrete level (one out of a possible four) for specifying the safety integrity requirements of

the safety functions to be allocated to the E/E/PE safetyrelated systems where Safety Integrity Level 4 has the highest

level of safety integrity and Safety Integrity Level 1 has the lowest.

Instruction Manual Supplement

D103546X012

A41 Valve

June 2017

SIS: Safety Instrumented System – Implementation of one or more Safety Instrumented Functions. A SIS is composed

of any combination of sensor(s), logic solver(s), and final element(s).

Related Literature

Hardware Documents:

Fisher A41 Valve Instruction Manual

Instruction Manual:

A41: D500211X012

Guidelines/References:

D Safety Integrity Level Selection – Systematic Methods Including Layer of Protection Analysis, ISBN 1556177771,

ISA

D Control System Safety Evaluation and Reliability, 2nd Edition, ISBN 1556176388, ISA

D Safety Instrumented Systems Verification, Practical Probabilistic Calculations, ISBN 1556179099, ISA

Reference Standards

Functional Safety

D IEC 61508: 2000 Functional safety of electrical/electronic/ programmable electronic safetyrelated systems

D ANSI/ISA 84.00.012004 (IEC 61511 Mod.) Functional Safety – Safety Instrumented Systems for the Process Industry

Sector

Product Description

The Fisher A41 valve features an eccentrically mounted disc with a soft or stainless steel seal ring. Soft seals provide

excellent sealing capabilities in both flow directions. The metal seal ring provides excellent shutoff against pressure

applied in the recommended flow direction for both liquid and gas applications. The NOVEX and Phoenix III metal seals

are available for demanding applications requiring excellent shutoff capabilities. The double D shaft combines with a

variety of power and manual actuators to form a reliable, high-performance valve suitable for many power applications

requiring tight shutoff. It is typically used with other interface components (valve actuator and positioner or solenoid

valve) to provide a final element subsystem for a Safety Instrumented Function (SIF).

Designing a SIF Using Fisher A41 Valves

Safety Function

When the valve's actuator is deenergized, the actuator and valve shall move to its failsafe position. Depending on

which configuration is specified fail–closed or failopen, the actuator will rotate the valve disk to close off the flow path

through the valve body or open the flow path through the valve body.

Instruction Manual Supplement

D103546X012

A41 Valve

June 2017

The A41 valve is intended to be part of final element subsystem as defined per IEC 61508 and the achieved SIL level of

the designed function must be verified by the designer.

Pressure, Temperature, and Environmental limits

The designer of a SIF must check that the product is rated for use within the expected environmental limits. Refer to

the A41 valve product bulletin for environmental limits.

Application limits

The materials of construction of A41 valves are specified in the product bulletin. A range of materials are available for

various applications. The serial card will indicate what the materials of construction are for a given valve. It is especially

important that the designer check for material compatibility considering onsite chemical contaminants and

environmental conditions. If the A41 valve is used outside of the application limits or with incompatible materials, the

reliability data provided becomes invalid.

Diagnostic Response Time

The A41 valve does not perform any automatic diagnostic functions by itself and therefore has no diagnostic response

times of its own. However, automatic diagnostics of the final control subsystem may be performed such as Partial

Valve Stroke Testing (PVST). This typically will exercise the valve over a small percentage of its normal travel without

adversely affecting the flow through the valve. If any failures of this PVST are automatically detected and annunciated,

the diagnostic response time will be the PVST interval time. The PVST must be performed 10 times more often than an

expected demand in order for credit to be given for this test. Typically this test could be performed monthly or weekly.

Design Verification

A detailed Failure Mode, Effects, and Diagnostics Analysis (FMEDA) report is available from Emerson. This report details

all failure rates and failure modes as well as the expected lifetime.

The achieved Safety Integrity Level (SIL) of an entire Safety Instrumented Function (SIF) design must be verified by the

designer via a calculation of PFDAVG considering architecture, proof test interval, proof test effectiveness, any

automatic diagnostics, average repair time and the specific failure rates of all products included in the SIF. Each

subsystem must be checked to assure compliance with minimum hardware fault tolerance (HFT) requirements.

When using A41 valves in a redundant configuration, a common cause factor of at least 5% should be included in the

Safety Integrity calculations. This value is dependent on the level of common cause training and maintenance in use at

the end user's facility.

The failure rate data listed the FMEDA report is only valid for the useful lifetime of A41 valves. The failure rates will

increase after this time period. Reliability calculations based on the data listed in the FMEDA report for mission times

beyond the useful lifetime may yield results that are too optimistic, i.e. the calculated Safety Integrity Level will not be

achieved.

Instruction Manual Supplement

D103546X012

A41 Valve

June 2017

SIL Capability

Systematic Integrity

Figure 2. exida SIL 3 Capable

The product has met manufacturer design process requirements of IEC 61508 Safety Integrity Level 3. These are

intended to achieve sufficient integrity against systematic errors of design by the manufacturer. A Safety

Instrumented Function (SIF) designed with this product must not be used at a SIL level higher than stated without

“prior use” justification by the end user or diverse technology redundancy in the design.

Random Integrity

A41 valves are classified as a Type A device according to IEC 61508, having a hardware fault tolerance of 0. The

complete final element subsystem, with a Fisher butterfly valve as the final control element, will need to be evaluated

to determine the Safe Failure Fraction of the subsystem. If the SFF for the entire final element subsystem is between

60% and 90%, a design can meet SIL 2 @ HFT=0.

Safety Parameters

For detailed failure rate information refer to the Failure Modes, Effects and Diagnostic Analysis Report for the A41

valve.

Connection of the Fisher A41 Valve to the SIS Logic-solver

The final element subsystem (consisting of a positioner, actuator, and A41 valve) is connected to the safety rated logic

solver which is actively performing the Safety Function as well as any automatic diagnostics designed to diagnose

potentially dangerous failures within the A41 valve , actuator and any other final element components, (i.e. Partial

Valve Stroke Test).

Instruction Manual Supplement

D103546X012

A41 Valve

June 2017

General Requirements

The system's response time shall be less than process safety time. The final control element subsystem needs to be

sized properly to assure that the response time is less than the required process safety time. The A41 valve will move

to its safe state in less than the required SIF's safety time (a typical value is 3 seconds) under the specified conditions.

All SIS components including the A41 valve must be operational before process startup.

The user shall verify that the A41 valve is suitable for use in safety applications.

Personnel performing maintenance and testing on the A41 valve shall be competent to do so.

Results from the proof tests shall be recorded and reviewed periodically.

The useful life of the A41 valve is discussed in the Failure Modes, Effects, and Diagnostic Analysis Report for the Fisher

A41 valve.

Installation and Commissioning

Installation

The Fisher A41 valve must be installed per standard practices outlined in the appropriate instruction manual.

The environment must be checked to verify that environmental conditions do not exceed the ratings.

The A41 valve must be accessible for physical inspection.

Physical Location and Placement

The Fisher A41 valve shall be accessible with sufficient room for the actuator, pneumatic connections, any other

components of the final control element. Provisions shall be made to allow for manual proof testing.

Pneumatic piping to the actuator shall be kept as short and straight as possible to minimize the airflow restrictions and

potential clogging. Long or kinked pneumatic tubes may also increase the valve closure time.

The A41 valve shall be mounted in a low vibration environment. If excessive vibration can be expected special

precautions shall be taken to ensure the integrity of pneumatic connectors or the vibration should be reduced using

appropriate damping mounts.

Instruction Manual Supplement

D103546X012

A41 Valve

June 2017

Operation and Maintenance

Suggested Proof Test

The objective of proof testing is to detect failures within the A41 valve that is not detected by any automatic

diagnostics of the system. Of main concern are undetected failures that prevent the Safety Instrumented Function

from performing its intended function.

The frequency of proof testing, or the proof test interval, is to be determined in reliability calculations for the Safety

Instrumented Functions for which A41 valves are applied. The proof tests must be performed more frequently than or

as frequently as specified in the calculation in order to maintain the required Safety Integrity of the Safety

Instrumented Function.

The proof test shown in table 1 is recommended. The results of the proof test should be recorded and any failures that

are detected and that compromise functional safety should be reported to Emerson. The suggested proof test consists

of a full stroke of the A41 valve.

The person(s) performing the proof test of A41 valves should be trained in SIS operations, including bypass

procedures, valve maintenance and company Management of Change procedures. No special tools are required.

Table 1. Recommended Full Stroke Proof Test

Step Action

1Bypass the safety function and take appropriate action to avoid a false trip.

2Interrupt or change the signal/supply to the actuator to force the actuator and valve to perform a full stroke to the FailSafe state and

confirm that the Safe State was achieved and within the correct time.

3Restore the supply/signal to the actuator and confirm that the normal operating state was achieved.

4Inspect the A41 valve and the other final control element components for any leaks, visible damage or contamination.

5Record the test results and any failures in your company's SIF inspection database.

6Remove the bypass and restore normal operation.

Repair and replacement

Repair procedures in the appropriate valve instruction manual must be followed.

Manufacturer Notification

Any failures that are detected and that compromise functional safety should be reported to Emerson. Please contact

your Emerson sales office or Local Business Partner.

Appendix A

Sample Startup Checklist

This appendix provides a Sample Startup Checklist for Fisher A41 valves. A startup checklist will provide guidance

during the final control elements employment.

Instruction Manual Supplement

D103546X012

A41 Valve

June 2017

Start-Up Checklist

The following checklist may be used as a guide to employ A41 valves in a safety critical SIF compliant to IEC61508.

# Activity Result Verified

By Date

Design

Target Safety Integrity Level and PFDAVG determined

Correct valve mode chosen (Failclosed, Failopen)

Design decision documented

Pneumatic compatibility and suitability verified

SIS logic solver requirements for valve tests defined and documented

Routing of pneumatic connections determined

SIS logic solver requirements for partial stroke tests defined and

documented

Design formally reviewed and suitability formally assessed

Implementation

Physical location appropriate

Pneumatic connections appropriate and according to applicable codes

SIS logic solver valve actuation test implemented

Maintenance instructions for proof test released

Verification and test plan released

Implementation formally reviewed and suitability formally assessed

Verification and Testing

Electrical connections verified and tested

Pneumatic connection verified and tested

SIS logic solver valve actuation test verified

Safety loop function verified

Safety loop timing measured

Bypass function tested

Verification and test results formally reviewed and suitability formally

assessed

Maintenance

Tubing blockage / partial blockage tested

Safety loop function tested

Emerson Automation Solutions

Marshalltown, Iowa 50158 USA

Sorocaba, 18087 Brazil

Cernay, 68700 France

Dubai, United Arab Emirates

Singapore 128461 Singapore

www.Fisher.com

The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not

to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are

governed by our terms and conditions, which are available upon request. We reserve the right to modify or improve the designs or specifications of such

products at any time without notice.

Fisher is a mark owned by one of the companies in the Emerson Automation Solutions business unit of Emerson Electric Co. Emerson Automation Solutions,

Emerson, and the Emerson logo are trademarks and service marks of Emerson Electric Co. All other marks are the property of their respective owners.

Neither Emerson, Emerson Automation Solutions, nor any of their affiliated entities assumes responsibility for the selection, use or maintenance

of any product. Responsibility for proper selection, use, and maintenance of any product remains solely with the purchaser and end user.

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