Samson 3241 Bedienungsanleitung

Competence in Functional Safety

Functional safety of globe

valves, rotary plug valves, ball valves and butterﬂy valves

MANUAL

SMART IN FLOW CONTROL.

Competence in Functional Safety

Functional safety of globe valves, rotary plug valves, ball valves and butterﬂy valves

SAMSON

AIR TORQUE · CERA SYSTEM · KT-ELEKTRONIK · LEUSCH

PFEIFFER · RINGO · SAMSOMATIC · STARLINE · VETEC

Founded in 1907, SAMSON has since become a worldwide

leader in the manufacture of expertly engineered control

valves.

SAMSON has over 50 subsidiaries, amongst them noted

manufacturers of special valves.

With these subsidiaries, SAMSON is represented in over

80 countries to assist its customers on all continents.

Competence in Functional Safety

Functional safety of globe valves, rotary plug valves, ball valves and butterﬂy valves

Table of contents

1 Scope ...............................................................................................................................................................4

2 Validity of this manual ........................................................................................................................................4

3 Intended use of this manual.................................................................................................................................5

4 General aspects of functional safety.....................................................................................................................6

4.1 Standards, terms and abbreviations .............................................................................................................6

4.2 Determining the safety integrity level ............................................................................................................8

4.3 Hardware fault tolerance ............................................................................................................................9

5 Intended use of control valves in safety-instrumented systems................................................................................10

5.1 General control valve requirements............................................................................................................12

5.2 Globe valve requirements.......................................................................................................................... 13

5.3 Ball valve requirements .............................................................................................................................15

5.4 Butterﬂy valve requirements.......................................................................................................................16

5.5 Rotary plug valve requirements..................................................................................................................18

5.6 Proof tests and service life .........................................................................................................................18

6 Installation, piping and wiring ...........................................................................................................................19

6.1 Mechanical and pneumatic installation.......................................................................................................19

6.2 Electrical installation .................................................................................................................................20

6.3 Installation of control valves.......................................................................................................................20

7 Applicable device documentation ......................................................................................................................22

8 Appendix 1 – Manufacturer‘s declarations .........................................................................................................22

9 Appendix 2 − Example of a checklist for a ﬁnal element......................................................................................30

Competence in Functional Safety

Functional safety of globe valves, rotary plug valves, ball valves and butterﬂy valves

1 Scope

Valves and the associated actuators are used to isolate pipelines in safety-instrumented systems. Alternatively, they can

also be used for pressure relief, i.e. by completely opening valves.

2 Validity of this manual

This manual applies to control valves manufactured by the following companies within SAMSON:

 SAMSON AG

 LEUSCH GmbH Industriearmaturen

 PFEIFFER Chemie-Armaturenbau GmbH

 VETEC Ventiltechnik GmbH

Refer to the manufacturer‘s declarations in Appendix 1 of this manual for the valve models concerned.

The individual versions of the valves can be identiﬁed by their nameplates

10 EB 8310-7 EN

Markings on the device

2 Markings on the device

2.1 Actuator nameplate

The nameplate is stuck on the diaphragm casing. It includes all details required to identify the

actuator:

2 Conguration ID

3 Serial number

4 Actuator area

5 Bench range in bar

6 Bench range in psi

7 Operating travel in mm

8 Operating range in bar

9 Operating range in psi

Permissible supply pressure pmax in bar

Permissible supply pressure pmax in psi

Symbol indicating fail‑safe action

Actuator stem extends (FA)

Actuator stem retracts (FE)

Manual override

Connecting thread

Diaphragm material

Date of manufacture

15 12 6

10 11

SAMSON 3271

Made in Germany

Var-ID

Serial no.

Fig.1: Nameplate

Example of a nameplate for a Type 3241

Valve with Type 3271 or Type 3277 Pneumatic

Actuator manufactured by SAMSON AG

12 EB 8015 EN

Markings on the control valve

2 Markings on the control valve

2.1 Valve nameplate

6 8

12 13

10 11

14 15 16 17 18

1…5 9

SAMSON

Fig.1: Valve nameplate

1…5 PED (Pressure Equipment Directive), "Art. 4, Abs. 3"

ID of the notied body, uid group, and category

6 Type designation

8Material

9Year of manufacture

10 Valve size:

DIN: DN · ANSI: NPS· JIS: DN…A/B

11 Pressure rating:

DIN: PN · ANSI: CL · JIS: K

12 Order no. with modication index

For after-sales service orders: AA prex

13 Position in order

For after-sales service orders: conguration ID

14 Flow coefcient:

DIN: KVS · ANSI: CV · JIS: CV

15 Characteristic:

%: equal percentage · Lin: linear · NO/NC: quick opening

16 Seat/plug seal:

ME: metal (see section3.3)

HA: carbide metal

ST: Stellite® facing

KE: ceramic

PT: soft seal with PTFE

PK: soft seal with PEEK

17 Seat code (trim material) · On request

18 Pressure balancing:

DIN: D · ANSI: B · JIS: B

19 Flow divider:

1: StI · 3: StIII

20 Country of origin

21 PSA version

Competence in Functional Safety

Functional safety of globe valves, rotary plug valves, ball valves and butterﬂy valves

3 Intended use of this manual

This manual is intended to assist planners and operators during the integration of control valves into a safety loop as

part of the safety function and to enable them to safely operate control valves.

This manual contains information, safety-related data and warnings concerning the functional safety in accordance

with IEC 61508 and concerning the application in the process industry in accordance with IEC 61511. It does not con-

tain any particular details on other safety requirements, such as explosion protection or electrical safety.

Safety-instrumented systems are to be commissioned and maintained by qualiﬁed personnel only. Refer to the corre-

sponding mounting and operating instructions of the valve.

Competence in Functional Safety

Functional safety of globe valves, rotary plug valves, ball valves and butterﬂy valves

4 General aspects of functional safety

4.1 Standards, terms and abbreviations

Abbreviation Designation Description

SIL Safety Integrity Level One of four discrete levels for specifying the safety integrity requirements

of the safety functions to be allocated to the E/E/PE safety-related systems,

where SIL 4 has the highest level of safety integrity and SIL 1 has the lowest.

MTBF Mean Time Between Failures Mean time between two failures

MTTR Mean Time To Restoration Mean time between the occurrence of a failure in a device or system and its

repair

HFT Hardware Fault Tolerance Capability of a functional unit to continue executing the demanded function

in case of faults or deviations.

λsd Failure rate for all safe detected

failures

λsu Failure rate for all safe undetected failures

λdd Failure rate for all dangerous detected failures

λdu Failure rate for all dangerous undetected

failures

SFF Safe Failure Fraction Fraction of non-hazardous failures, i.e. the fraction of failures without the

potential to set the safety-related system to a dangerous or impermissible

state.

PFDavg Average Probability of Failure on

Demand

Average likelihood that a dangerous safety function failures occurs on

demand.

TITest Interval between life testing of the safety

function

Average likelihood that a dangerous safety function failures occurs on

demand.

Low demand

mode

Low demand mode of operation Low demand mode is where the frequency of demands for operation made

on a safety-related system is no greater than one per year and no greater

than twice the proof test frequency.

Competence in Functional Safety

Functional safety of globe valves, rotary plug valves, ball valves and butterﬂy valves

Abbreviation Designation Description

MooN Voting “M out of N“ (e. g. 2oo3) Classiﬁcation and description of the safety-related system regarding redun-

dancy and the selection procedure used.

• “N“ indicates how often the safety function is carried out (redundancy).

• “M“ determines how many channels must work properly.

Example: Pressure measurement in 1oo2 architecture

A safety-instrumented system decides that a speciﬁed pressure limit has

been exceeded if one of two pressure sensors reaches this limit. In a 1oo1

architecture, there is only one pressure sensor.

MooND Voting “M out of N“ with diagnostics

Relevant standards

Norm Designation

IEC 61508

Parts 1 to 7

Functional safety of electrical/electronic/pro-

grammable electronic safety-related systems

IEC 61511

Parts 1 to 3

Functional safety – Safety instrumented systems

for the process industry sector

VDI 2180

Parts 1 to 5

Safeguarding of industrial process plants by

means of process control engineering

Terms and deﬁnitions

Term Deﬁnition

Dangerous failure Failure with the potential to set the safety-related system to a dangerous or inoperative state.

Safety-related system A safety-related system carries out the safety functions needed to establish or maintain a safe state,

e.g. in a plant.

Example: Pressure measuring instrument, logic unit (e.g. limit switch) and valve form a safety-related system.

Safety function A deﬁned function carried out by a safety-related system in order to establish or maintain a safe state of

the plant, under consideration of a speciﬁed dangerous incident.

Example: Pressure limit monitoring

Competence in Functional Safety

Functional safety of globe valves, rotary plug valves, ball valves and butterﬂy valves

4.2 Determining the safety integrity level

The achievable safety integrity level (SIL) is determined by the following safety-related data:

 Average probability of failure on demand (PFDavg)

 Hardware fault tolerance (HFT)

 Safe failure fraction (SFF)

The following table in accordance with IEC 61508 and IEC 61511 shows how the safety integrity level (SIL)

depends on the average probability of failure on demand (PFDavg). It is based on low demand mode of

operation, i.e. the frequency of demands on a safety-related system is no greater than once per year.

Safety integrity level (SIL) PFDavg (low demand mode)

4≥10-5 to <10-4

3≥10-4 to <10-3

2≥10-3 to <10-2

1≥10-2 to <10-1

PFDavg in low demand mode of operation according to IEC 61508-1, Table 2

The sensor, logic unit and ﬁnal element form a safety-related system that performs a safety function.

Sensor

e.g. pressure

measuring instrument

PFDavg ≤X % ≤X % ≤X %

Logic unit

e.g. PLC

Final element

e.g. valve

The average probability of failure on demand (PFDavg = sum of sensor, logic unit and ﬁnal element failures) must be within

the range of the demanded safety integrity level (SIL) in case of demand as listed in the above table.

Competence in Functional Safety

Functional safety of globe valves, rotary plug valves, ball valves and butterﬂy valves

4.3 Hardware fault tolerance

In the process industry, the achievable SIL classes for sensors, ﬁnal elements and non-programmable logic modules,

such as isolating ampliﬁers and relays, are restricted in accordance with IEC 61511 as shown in the following table.

Safety integrity level (SIL) Minimum required hardware failure tolerance (HFT)

1 0

2 1

3 2

4 Special requirements (refer to IEC 61508)

Minimum required hardware failure tolerance (HFT) according to IEC 61511-1, Table 6, for the process industry

The minimum required hardware failure tolerance can be decreased by one if the following requirements are met:

 The device is proven in use.

Take this into account when selecting devices!

 The device only allows process-relevant parameters to be set, e.g. measuring range, upscale or downscale function

in case of failure.

Final elements do not have any conﬁgurable functions.

 The process-relevant parameters of the device are access-protected, e.g. by jumper or password.

Final elements do not have any conﬁgurable functions.

 The function requires a SIL less than 4.

A ﬁnal element has a single-channel design, resulting in a hardware failure tolerance (HFT) = 0. This results in a single-

channel application up to SIL 1 or up to SIL 2 for proven-in-use devices.

At least two redundant devices are required for SIL 3 with proven-in-use devices.

At least three redundant devices are required for SIL 3 without proven-in-use devices.

Competence in Functional Safety

Functional safety of globe valves, rotary plug valves, ball valves and butterﬂy valves

5 Intended use of control valves in

safety-instrumented systems

Responsibility

The reliability of mechanical components is signiﬁcantly affected by the operating condi-

tions and, as a result, by systematic failures. This needs to be taken into account when

selecting and sizing devices.

Safety-instrumented function

During normal operation, the signal pressure is applied to the pneumatic actuator. To

meet the requirements of the safety-instrumented function, the actuator is usually vented

by a solenoid valve. The force of the actuator springs moves the valve to its end position,

i.e. the valve is either completely opened or closed.

The end position of the valve must not be impeded by mechanical equip-

ment, such as travel stops or handwheels, under any circumstances.

When the signal pressure is applied to the actuator again, the valve moves to the corre-

sponding position. If the actuator is to be locked after a case of demand, this must be

ensured by the operator using suitable means.

Operator

Features of ﬁnal elements

 Contact with the process media may cause systematic failure and, as a result, affect the

safety-related availability of the safety-instrumented systems. The inﬂuence of speciﬁc

process conditions must be analyzed and taken into account during sizing and main-

tenance.

These conditions arise from process requirements. To rule out systematic failure, we re-

commend creating a loop data sheet according to the German standard VDI 2180-5,

section 4 (recommendations for ﬁnal elements).

In case of doubt, consult the manufacturer for valve sizing.

To reduce systematic failure, diverse redundancies may be advantageous (e.g. globe

valve and ball valve).

Operator

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