Technical Catalog Literature
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1. with DCS integration Type of panel A D With LED indicator lights eSB With LCD touchscreen display a a With DCS integration 5 5 50 SIL version x 9 3 O 93 02 32M 05004E Honeywell 5 MAXON PSCHECK PARTIAL STROKE TECHNOLOGY MAXON PSCHECK panel 3 to 5 valve systems J el L O Honeywell J ej L O with DCS integration SIL version Dimensions in mm unless stated otherwise Type of pane x B C D _ With LED indicator light ee 887 457 With LCD touchscreen display x w o 6 d With DCS integration w o o r Sieso S TO 6 www maxoncorp com 32M 05004E MAXON PSCHECK PARTIAL STROKE TECHNOLOGY MAXON PSCHECK panel 6 to 9 valve systems O O with DCS integration O Type of pane With LCD touchscreen display 762 With DCS integration 914 32M 05004E MAXON PSCHECK PARTIAL STROKE TECHNOLOGY INSTALLATION OPERATION AND MAINTENANCE INSTRUCTIONS Please read the operating and mounting instructions before using the equipment Install the equipment in compliance with the prevailing regulations Bedrijfs en montagehandleiding voor gebruik goed lezen Apparaat moet volgens de geldende voorschriften worden geinstalleerd Lire les instructions de montage et de service avant utilisation Lappareil doit imperative2. MAXON PSCHECK PARTIAL STROKE TECHNOLOGY COMPARE VALVE HISTORICAL TRENDING DATA Ability to switch between three different screens by changing the number of captured data points enabling better short and long term viewing of the trending information VIEW ALARM HISTORY Captures all alarms the dates of the alarms and valve testing information when either a soft alert alarm or a hard failure alarm is triggered The system will track all alarm instances over the life of the valve MANUAL TEST Ability to start an immediate manual test on the valves by pushing a button on the panel an icon on the touchscreen display or initiated via the DCS dependent on the configuration ordered The test will return immediate results on the valve s performance and will not interfere with any pre set automatic tests nor will it interfere with any of the valve or burner management functions AUTOMATIC TEST The unit will ship from the factory with all systems pre set to a monthly partial stroke test schedule SET FREQUENCY OF TEST In systems with the touchscreen display or DCS connection the customer has the option to change the frequency of the automatic test timing to daily weekly bi weekly monthly bi monthly annually none or a custom Set test rate SET LIMITS ON ALARMS The unit will ship with factory set limits on when a hard or soft alarm will trigger indicating that the valve s performance is degrading and maintenance should be
3. MAXON Series 8000 Valve is a pneumatically operated fuel shut off valve requiring compressed air for actuation The MAXON Series 8000 Valve will open or close by the addition of a control voltage signal and removal of the signal will cause a fast acting return to the at rest position Options are available in both normally closed and normally open versions They are also available in optional configurations that meet hazardous location requirements and fire safe trim configurations that meet API OFA Cast iron carbon steel low temperature carbon steel and stainless steel body assemblies with internal trim options to handle general purpose or corrosive gases oxygen compatibility NACE compliance Ambient temperature ranges of 58 F 50 C to 140 F 60 C gas temperature range of 58 F 50 C to 212 F 100 C Actuator assemblies are field replaceable and available in 120VAC 50 60 Hz 240VAC 50 60 Hz and 24VDC with low power option rated for NEMA 4 NEMA 4X and IP 65 MAXON Series 8000 Valves meet Fluid Control Institute FCI 70 2 control valve standard for Class VI seat leakage MAXON Series 8000 Valve nameplate and abbreviations Consult the nameplate on your MAXON Series 8000 safety shut off valve This lists the maximum operating pressure temperature limitations voltage requirements and service conditions of your specific valve Do not exceed nameplate ratings Visual indication determined by text color and symbol valv
4. Type 4X XX Special 1 Panel Inlet Voltage X Special A 24V DC Series B 110VAC SIL Rated PST MAXON PSCHECK C 220VAC N No X Special Y Yes Valve Voltage Area Classification A 24V DC A General purpose X Special B Class I Division 2 X Special Pressure Transducer N No Language X Special 0 English Automated Test Interval A Daily B Weekly C Bi weekly D Monthly E Bi monthly F Annually G None X Special 1 Up to 20 valves by special request 2 www maxoncorp com 32M 05004E MAXON PSCHECK PARTIAL STROKE TECHNOLOGY SPECIFICATIONS The MAXON PSCHECK Partial Stroke Technology system is offered in a variety of configurations to offer full control of a wide range of industrial processes through regularly scheduled partial stroke testing of the MAXON Series 8000 Shut off Valves Panel sizes Four panel sizes are available based on the number of MAXON Series 8000 Shut off Valves in each system and the SIL rating e 20 x 20 x 8 panel for 1 to 2 valve systems 24 x24 x 8 panel for 3 to 5 valve systems 36 x30 x 12 panel for 6 to 9 valve systems 36 x36 x 12 panel for 1 to 9 valve systems SIL rated Panel configurations Three configuration options are available LED indicator lights no display uses manual buttons and indicator lights to communicate testing results PASS FAIL only not SIL capable e LCD touchscreen display color graphic displ
5. i Fr za me 3 PTT me Me me AAF eq FA ITT IIT olleflellellektellellelle Nelle VALVE 8 gare CHANGES AN 7 a al E IO VALVE 9 Lists the installation date for each valve in the system based on information entered on PST System screen during commis sioning Also provides the customer with the ability to set a custom numerical valve identifier serial number factory location burner number etc to help identify the valve s physical location 14 www maxoncorp com 32M 05004E MAXON PSCHECK PARTIAL STROKE TECHNOLOGY FIGURE 6 SYSTEM SETUP TESTING PARAMETERS SYSTEM SETUP User PST System System Access Valve Profile 2 2 BACK SIGN IN HELP MAX TIME SOFT ALARM PRESET ms PRESET ms TEST FREQUENCY days VALVE 1 78 56 60 BI MONTHLY VALVE 2 456 785 i WSE VALVE 3 785 785 ANNUALLY VALVE 4 78 222 DAILY VALVE 5 48 45 VEEKS VALVE 6 78 55 ANNUALLY VALVE 7 Eee 9 MONTHLY VALVE 8 45 45 NONE SAVE CHANGES VALVE 9 47 5 ANNUALLY The MAXON PSCHECK ships with factory set limits for both hard and soft alarms Factory default value for the hard alarm is 500 ms and value for soft alarm is 50 ms When a soft alarm is triggered it indicates that the valve s performance is degrading and maintenance should be scheduled The soft alarm limit can be changed by the customer during the commissioning process This limit can be increased meaning the valve w
6. substances are present in the fuel line it will be necessary to inspect the valve to make certain it is operating properly If abnormal opening or closing is observed the valve should be removed from service Contact your MAXON representative for instructions Operator should be aware of and observe characteristic opening closing action of the valve Should operation ever become Sluggish remove valve from service and contact MAXON for recommendations Address inquiries to MAXON Local worldwide offices may be located at www maxoncorp com or by phoning 011 765 284 3304 Include valve serial number and nameplate information 32M 05004E Honeywell 17 MAXON PSCHECK PARTIAL STROKE TECHNOLOGY SIL SAFETY MANUAL FOR PSCHECK Purpose This manual gives the end user information on how to commission validate operate and maintain the PSCHECK system Introduction This manual provides necessary requirements for the IEC 61511 functional safety standards Reference Documents PRODUCT DOCUMENTS Follow the link below to the PSCHECK product literature on the MAXON website https www maxoncorp com index php src directory amp view product amp srctype display amp back product amp refno 466 amp category NaturalGasBurner Line amp pos 0 50 11 STANDARDS ANSI ISA 84 00 01 2004 IEC 61511 Mod Functional Safety Safety Instrumented Systems for the Process Industry Sector Description The PSCHECK system is a custom built pa
7. test considers the valve response a concern Setup the Test Frequency days How often the valve is tested automatically From System Setup screen select PST System Enter the date that each valve was installed Validation Since the PSCHECK unit provides a means of validating and verifying operation of MAXON Series 8000 Valve train consisting of 1 9 valves there is no specific Validation Checklist for this system 32M 05004E Honeywell 19 MAXON PSCHECK PARTIAL STROKE TECHNOLOGY Operation Maintenance Use the following table for basic operation maintenance of the PSCHECK system Table 2 Operation Maintenance Checklist Description HMI and DCS interface units After the unit is commissioned the testing will operate automatically Operation using HMI interface There is a manual test operation nobebasedofottisnendop I Oner a VARNE eeno M now be based off of this new day Mo getto that option from the Valve Health screen select the valve to be tested Select the START button to begin the test For more detailed information on auxiliary functions please consult the PSCHECK manual _ Note KMT and network communication feedback is NOT within the SIL safety system _ Operation using DCS interface 2 Communication and operation via network supported via specified network protocol r Note Network communication feedback is NOT within the SIL safety system O discrete inputs and outp
8. user 32M 05004E Honeywell 21 Commercial amp Industrial Combustion C amp IC North America MUNCIE INDIANA USA Maxon 201 East 18th Street P O Box 2068 Muncie IN 47307 0068 Tel 765 284 3304 Fax 765 286 8394 GOLDEN VALLEY MINNESOTA USA Honeywell Automation and Control Solutions 1985 Douglas Drive North Golden Valley MN 55422 3992 Canada Sales Office Maxon Industrial Equipment 3333 Unity Drive Mississauga Ontario L5L 3S6 Tel 800 489 4111 Fax 855 262 0792 European Sales Office Maxon International BVBA Luchthavenlaan 16 18 1800 Vilvoorde Belgium Tel 32 2 255 09 09 Fax 32 2 251 82 41 Asia Pacific Sales Office Maxon 17 Changi Business Park Central 1 Singapore 486073 Tel 65 6580 3358 Fax 65 6580 3345 China Sales Office Maxon Combustion Equipment Shanghai Co Ltd Ist Floor amp Section A 4th Floor 225 Meisheng Road Wai Gao Qiao Free Trade Zone Pudong New Area Shanghai 200131 P R China Tel 86 21 5866 1166 Fax 86 21 5868 1569 India Sales Office Maxon 53 54 56 57 Hadapsar Industrial Estate Environmental amp Combustion Controls Sapphire Building 2nd Floor A Wing Pune 411013 India Tel 91 98 50907894 91 20 66008330 91 20 66008509 Sales Offices amp Representatives Worldwide www maxoncorp com customer honeywell com 32M 05004E Metric version J uly 2014 Printed in USA 2014 Honeywell International Inc Honeywell
9. MAXON PSCHECK Partial Stroke Technology Technical Catalog MAXON PSCHECK PARTIAL STROKE TECHNOLOGY TABLE OF CONTENTS Features and benefits acars aaa AAEE E Eiaa 1 PIO GUCTCOS CIID TON siec aaa aa a A 1 Partial Stroke Testing technology isidis einde sdannanuhernnnddeninndande adanan ainina aaaea aaa Aaaa Kaai aaia 1 Applical0 s ua aQ Su aa aa aaa aa aaa aaa ENHE aaa 1 MOd el mmb er osscar aaa aeaa p a yaa sua S kaa wsdususs 2 Specificaliongu sas seandededenwadasausavanneeddedkcuacbdatievansabinineddsuclsuaualicsudusuddeuuusasusnddeuvsiariencuuencsduacutanads 3 Panel SIZES susu shahi kau L astay aaa eeens mute tates 3 Pale IMCOMMO Ua 0 uy umu ykuna akaun esmee aaa iON 3 Syst elcapabiliieS u L u u u SS uu m u u a a u ua a sata 3 DIMENSIONS siasa naaa Aaaa aaa a Aaaa aaa aa aa aLaaa Eaa 5 MAXON PSCHECK panel 1 to 2 valve systems rr 5 MAXON PSCHECK panel 3 to 5 valve systems rr 6 MAXON PSCHECK panel 6 to 9 valve systems r rr 7 Installation Operation and maintenance instructions nssssssssuunsennsrnnsnennennnnnsnnnnnnnnnnnnnsnnsnnnnnnnsnensnnnnennnnnsnsnnnnnnnnnnrnnnnnnnnnnnn 8 Deos e olde lg ert etre terre ree ere ner reer un iays ns asmia ne ne errr ree ee 9 DEMUS orsa y STAIN GOS u Grup Sis tenet 9 MAXON Series 8000 Valve description n nsn 10 Operating instructions LED in
10. ay HMI communicates valve test status test frequency valve health trends and alarm history e DCS integration plain front panel download data to Compact Flash CF drive with exported information available as csv file System capabilities Specific capabilities of each MAXON PSCHECK panel are based on the number of valves in the system and the panel configuration Table 1 lists all functions and their availability A summary of features and capabilities is listed below along with brief descriptions for each function PARTIAL STROKE TEST VERIFICATION OF TEST PASS FAIL The partial stroke test can be run manually or automatically at pre set times Depending on the system capabilities the valve s health status will be conveyed either by LED indicator lights on the panel via an icon on the touchscreen display or via direct communication to the DCS DATA LOGGING Valve health trending data is captured in non volatile microprocessor memory and will retain all of the valve health information for up to 10 years or longer dependent on how many times a year the valve partial stroke test is run VALVE DEGRADATION ERROR DETECTION Tests performed by MAXON PSCHECK systems will identify a soft or hard failure on the MAXON Series 8000 shut off valve by checking the amount of time required for the valve to trip signaling a capability to either open or close The longer time it takes to trip the valve indicates potential performance issue
11. dicator version nr 11 Operating instructions LCD touchscreen display version 12 Maintenance instructions nrnna aneceomeehemanare cumin 17 SIL Safety Manual foFPSCHECKT k aa aa aaaea aa aa aAa aa aaa aaa Aa aa anaa Aaaa aaan aN 18 PUDO O get a atte Raa acti oo aa aan Ene eeen nn en 18 HNO CUETO Na uu A u u u usus ss 18 Reference DOCUMEN OS ca cece conse saa ander dende 18 Bieistel gordel gE 18 SNIA td vant es eenander 18 ot OVO eaa entente aanannsen 18 General REYUrEMENS inenen bemad at aa a a uu ha daarden 19 COMAMUSSION ING MEE 19 VON Seereederei ennn eeens aT 19 Operaton MaintenahCE mien eene 20 Falle Rate Data nternet enden nme 21 Safety Architecture Safety Boundary edt dente 21 FUEN O EGA HON u usupa ene aap ma etten mah Bs Sasa ts 21 Legal NOICE avers k uyum a u Vonden 21 www maxoncorp com 32M 05004E MAXON PSCHECK PARTIAL STROKE TECHNOLOGY FEATURES AND BENEFITS Improve plantsafety without interrupting operations e Maintain full control of an industrial combustion process by automatically partial stroking and testing of the shut off valve to ensure itis operating properly Identify potential performance issues so proper maintenance can be scheduled resulting in less operation downtime and lon ger production runs e When used with MAXON Series 8000 Shut off Valves the PSCHECK Partial Stroke Technol
12. e is shown in open position Visual indication determined by text color and symbol valve is shown in closed position pa _ p lt is partially open gt lt B VOS 1 2 Valve open switch es VCS 1 2 Valve closed switch es proof of closure 10 www maxoncorp com 32M 05004E MAXON PSCHECK PARTIAL STROKE TECHNOLOGY Operating instructions LED indicator version AVAILABLE IN 1 2 VALVE PANEL OR 3 5 VALVE PANEL CONFIGURATIONS 5 VALVE SYSTEM SHOWN The manual version of the MAXON PSCHECK offers factory set parameters for the hard alarms and partial stroke test frequency It will automatically run the partial stroke test based on the factory set intervals as well as manual testing at any time when prompted by the authorized user Manual testing will require keyed access to the panel to initiate test JV T MAXON A Honeywell Company www maxoncorp com PUSH TO TEST START VALVE 1 VALVE 2 VALVE 3 VALVE 5 PASSED PASSED PASSED PASSED VALVE 1 VALVE 5 FAILED FAILED Q A Switch to lock or unlock PSCHECK system Key required to unlock and run manual test One key will be used to allow access to all valves in system Push button to start manual test for all valves One start button is used to start testing of all valves in system Simultaneously The start button will flash while testing is underway and will remain flashing until the last valve has completed testing Pus
13. eration before and after its installation to insure proper SIL rated functionality Personnel operating maintaining the PSCHECK system must be competent to do so The PSCHECK system should be checked for any alarms that could be used to predict a possible valve failure The useful life of the PSCHECK system is based on the life stated by the manufacturers of the components used in the system construction See individual components manufacturer s documentation for details All components are considered replaceable Commissioning Use the following table to commission the PSCHECK system Table 1 Commissioning Checklist Description emove all shipping materials nsure no physical damage he unit must be mounted in a SIL 2 or lower rated environment ll four mounting points are being used he proper size rated bolts are used he panel is oriented correctly for proper HMI viewing he panel is properly grounded es nee The power is properly connected and does not compromise the rating of the enclosure Tre 10 propery connected and does nat compromise the rating ofthe enclosure The power wiresieables are rated and sized correcty 2 The O wiresfeables are rated and sized corect o Fu j C 1 Verify all protection devices at power up x jWeriyiMipowesuppope erty PLC powers up propery a WIUIGWSGIIEIE From Valve Health screen select any valve select System Setup Setup the Soft Alarm Preset ms The time before the valve stroke
14. etter predictive maintenance scheduling MAXON now offers a compelling Solution for a SIL 3 capable system with the MAXON Series 8000 pneumatic safety shut off valve combined with the MAXON PSCHECK partial stroke test technology APPLICATIONS MAXON PSCHECK Partial Stroke Technology can be used in any application that utilizes MAXON s Series 8000 Shut off Valves The PSCHECK and Series 8000 Valve are both SIL 2 compliant and when combined into a fully Safety Instrumented System a SIL 3 certification is possible No additional system add ons or non conforming hardware is required to attain SIL 3 certification 32M 05004E Honeywell 1 MAXON PSCHECK PARTIAL STROKE TECHNOLOGY MODEL NUMBER MAXON PSCHECK Partial Stroke Technology Configured Tem Number Standards System Size Language gt Q a a 5 A D i 5 6p O O is an Panel Inlet Voltage Valve Voltage Pressure Transducer Automated Test Communication Enclosure Rating SIL Rated Area Classification gt gt gt System Size Indication Type Communication 01 1 valve system A Status lighting A Ethernet 02 2 valve system B HMI display B ModBus 1761 NET 03 3 valve system C None DCS integration required C ModBus AIC 04 4 valve system X Special D None 05 5 valve system X Special 06 6 valve system Power Supply 07 7 valve system N No Enclosure Rating 08 8 valve system Y Yes A Type 12 09 9 valve system B
15. h button to stop manual test for all valves Valves have passed partial stroke test Green light stays on continuously and will remain illuminated for 24 hours after a testis completed Lights are numbered to indicate which valves passed testing Valves have failed partial stroke test Red light stays on continuously until valve passes test Lights are numbered to indicate which valve failed testing 32M 05004E Honeywell 11 MAXON PSCHECK PARTIAL STROKE TECHNOLOGY Operating instructions LCD touchscreen display version AVAILABLE IN 1 9 VALVE CONFIGURATIONS 9 VALVE SYSTEM SHOWN FIGURE 1 VALVE STATUS SCREEN The initial screen on the LCD touchscreen display following system boot up shows all of the valves in the MAXON PSCHECK configuration First time MAXON PSCHECK unit is powered valves will appear with green check marks see below Following testing each valve will display results of the most recent partial stroke testing TATE ncn Alarm History System Setup 2 SIGN IN HELP TOOLS Valve Status Valve Status Tap on valve icon for detail on valve icon for detail Green check mark indicates that the valve has PASSED and is operating properly Yellow exclamation point indicates that the valve s performance is in ALERT mode and is degrading and a Red X indicates the valve has FAILED the partial stroke test To view details for an individual valve touch the valve icon on the touchscreen display This will sho
16. ill run longer without any warnings or alerts or can be lowered meaning the system will alarm out to indicate the valve s degradation sooner Touch the value to be changed in the Soft Alarm Preset ms column enter a new number and touch Save Changes in the lower left corner of the screen Touch the Test Frequency buttons in right column to change test schedule Available choices are daily weekly bi weekly monthly bi monthly annually none or customer specified Touch Save Changes after making changes to the test frequency 32M 05004E Honeywell 15 MAXON PSCHECK PARTIAL STROKE TECHNOLOGY FIGURE 7 VALVE HEALTH F zie y G VENTEN ENUM Alarm History System Setup 2 2 BACK 4 ae signin HP User K N H i 7 J E 2 3 4 HARD ALARM K VALVE POSITION OPEN TEST F SCHEDULE L BI MONTHLY J L PST TIME 0 ms M LAST TEST 00 00 0000 r 1 N START Y scale 60 Change Trend View KISS S P Q A Valve number selected Returns to the previous screen Valve s normal position Normally closed shut off valves begin opening cycle immediately upon being powered Normally open vent valves begin to close immediately upon being powered All systems ship pre setto a monthly partial stroke test schedule The customer has the option to change the frequency of the test timing to daily weekly bi weekly monthly bi monthly annually none or custom Amount of time required for the valve to tri
17. ment tre install selon les reglementations en vigueur Betriebs und Montageanleitung vor Gebrauch lesen Ger t mu nach den geltenden Vorschriften installiert werden 8 www maxoncorp com 32M 05004E MAXON PSCHECK PARTIAL STROKE TECHNOLOGY The Installation Operating and Maintenance Instructions contain important information that must be read and followed by anyone operating or servicing this product Do not operate or service this equipment unless the instructions have been read IMPROPER INSTALLATION OR USE OF THIS PRODUCT COULD RESULT IN BODILY INJ URY OR DEATH Description MAXON PSCHECK partial stroke technology when combined with MAXON Series 8000 Pneumatic Shut off Valves can offer a SIL 3 capable system MAXON PSCHECK utilizes partial stroke testing technology to determine the status of the safefy shut off valves without shutting down or interrupting combustion system operations Data from the tests can be collected and trended to detect valve degradation giving process control plants better predictive maintenance and reducing the possibility of detected valve failures Frequent testing of the Series 8000 pneumatic safety shut off valve also helps clean the surface of the metal to metal valve seats which are enhanced by the wear in not out design feature Definitions of safety standards Standard Definition Explanation E measure of safety system performance Specifying the probability of a safety instr
18. nel consisting of an HMI and PLC This system is a testing device used to provide patented MAXON partial stroke testing on our Series 8000 safety shut off valves The system can be configured to operate the partial stroke testing on 1 to 9 valves The PSCHECK system is a system providing proof testing via a Partial Stroke Test for the MAXON Series 8000 safety shut off valves The proof test can be either automatically or manually initiated and checks the response of MAXON Series 8000 Safety Shut off Valves while in service In order to be considered a SIL diagnostic test the test must be automatically initiated by the PSCHECK SIL rated PLC In addition the completion of the test must be internally verified by confirmation of redundant feedback contacts Test failures must be annunciated by a discrete safety rated contact with a local visual indicator light for feedback Limits ENVIRONMENTAL LIMITS Refer to the PSCHECK catalog section for the environmental limits of the product APPLICATION LIMITS This productis designed to be used exclusively with MAXON Series 8000 safety shut off valves The current system limitation is a maximum of nine valves can be tested SIL Level The PSCHECK system was designed and built for the requirements of SIL 2 18 www maxoncorp com 32M 05004E MAXON PSCHECK PARTIAL STROKE TECHNOLOGY General Requirements All SIS components used in conjunction with the PSCHECK system must be tested for op
19. ogy can be incorporated into a Safety Instrumented System SIS that will meet SIL 3 performance requirements Configurations available for monitoring 1 to 9 valves per panel with choice of three user interface designs PRODUCT DESCRIPTION MAXON s PSCHECK Partial Stroke Technology will identify a potential early failure or signal a hard failure on the Series 8000 Pneumatic Shut off Valve by checking the amount of time required for the valve to trip signaling the valve s capability to open or close The longer time it takes to trip the valve indicates potential performance issues After the MAXON PSCHECK Partial Stroke Technology test has run the unit will signal a PASS FAIL result that can be seen either from an alarm LED touchscreen display indicator or communicated to the DCS directly When used in conjunction with MAXON Series 8000 Shut off Valve the MAXON PSCHECK captures this information and tracks the overall health of the valve plotting the results on an optional touchscreen display to show partial stroke testing results over the life of the valve This trending information shows a linear relationship between the degradation of the valve s performance indicating when the valve may potentially fail MAXON PSCHECK is offered in three different configurations scaled to fit any budget and installation requirement communicating its status via a manual LED push button panel interactive on board LCD touchscreen displa
20. p signaling a capability to either open or close Date of last partial stroke test Ability to start a manual test of any valve through the touchscreen display The test will return immediate results on the valve s health and will not interfere with any pre set automatic tests Expands trending graph to full screen mode Captures valve testing information and tracks the overall health of the MAXON Series 8000 shut off valve by plotting testing information to show trending over the life of the valve This trending information or predictive indicator shows a linear relationship between the installation health data vs the degradation of the valve s performance over the life of the O valve This trending data is used to indicate when the valve may require maintenance replacement or that it will probably fail Features ability to switch between three different screens changing the number of captured data points 10 60 or 120 enabling better short or long term viewing of the trending information The Y axis scale can be changed to allow user to zoom in and better analyze data U Returnto main menu valve status screen shown in Figure 1 oO www maxoncorp com 32M 05004E MAXON PSCHECK PARTIAL STROKE TECHNOLOGY Maintenance instructions Do not attempt field repair of valve body or actuator Any alterations void all warranties and can create potentially hazardous situations If foreign material or corrosive
21. s If the valve is degrading it will signal a soft failure alert if the valve fails it will indicate a failure EXPORT OF VALVE TRENDING INFORMATION It is simple to export the valve health trending data via a supplied Compact Flash CF drive The information is presented in a cSv format that can be modified for analysis audits and for presentation to regulatory or insurance authorities DATE VALVE BUILT A factory build date will be established in permanent memory DATE VALVE INSTALLED AND COMMISSIONED During the commissioning process the customer will be required to set the date the system is installed and run a manual partial stroke test to establish the baseline for the valve s health VALVE IDENTIFICATION LOCATION The customer has the ability to set a custom number for each valve to help identify its location TRENDING OF VALVE PERFORMANCE Diagnostics capture the valve testing information and track the overall health of the MAXON Series 8000 pneumatic safety shut off valve by plotting this information on a touchscreen display showing the valve s health trending over the life of the valve This trending information or predictive indicator shows a linear relationship between the initial installation health data vs the degradation of the valve s performance over the life of the valve This trending data is used to indicate when the valve may require maintenance replacement or that it will potentially fail 32M 05004E Honeywell 3
22. scheduled or that the valve has failed the test The hard alarm limit is factory set The soft alarm limit can be changed by the customer LCD touchscreen only during the commissioning process or ata later date This limit can be increased meaning the valve will run longer without any warnings or alerts or can be lowered meaning the system will alarm out indicating the valve s degradation sooner USER AUTHORIZATION For systems with a touchscreen display limits access to some functions based on type of user Manager or Operator For manual units with LED indicator lights a key is required to conduct a manual test Table 1 Available MAXON PSCHECK panel configurations Panel Configurations Panel Features LED LCD DCS Indicator Lights Touchscreen Integration Partial stroke test PASSIFAIL verifcaton tt Dakun O C r 5 Vale degradation erordetecton aw Export ofvalve ending information I e e Dave Payt Fast Date valve is installed and commissioned Fast t Valveidenticationfocaton TI Trending ofvalveperormance E S a Compare valve historical ending da S S View aam Stoy O o r Manualparialstoke test Keedaces tt Automaticaly run paral stole st o I S s Setfrequency oftest Fest o et mits for alarms User authorization keedacess ma 4 www maxoncorp com 32M 05004E MAXON PSCHECK PARTIAL STROKE TECHNOLOGY DIMENSIONS MAXON PSCHECK panel 1 to 2 valve systems
23. tallation date can be reset if the valve is replaced or repaired After entering the installation date for each valve run a manual partial stroke test to save the installation date in memory and establish a baseline for trending the valve s health Enter the date and run the test for each valve individually and repeat the process for each valve in the system 32M 05004E Honeywell 13 MAXON PSCHECK PARTIAL STROKE TECHNOLOGY FIGURE 4 SYSTEM SETUP SYSTEM ACCESS w Testing PST System j Valve Profile 2 PASSWORD PROTECTION Manager ob Screen Change a Valve Test Time G Valve Soft Alarm A Valve Hard Alarm E Valve Interval Time f Valve Test Start f Valve Test Stop Visually indicates which users have the capability to perform or change various functions ofthe PSCHECK system based on type of user Manager or Operator The permissions granted to Manager and Operator are factory set and cannot be changed by the user FIGURE 5 SYSTEM SETUP VALVE PROFILE PST System System Access i VALVE 1 Testing Valve Profile IN a Vi ollolfio O 7 A VALVE 2 J LC oll VALVE 3 r k P IOl CH H ollo Oro F Hono VALVE 4 VALVE 5 VALVE 6 iQ VALVE r f I 5 ii bo dll IO
24. umented system satisfactorily performing the required safety instrumented functions under all the stated conditions within a stated period of time SIL is required for Safety Instrumented Systems SIS The PSCHECK partial stroke test technology and the Series 8000 pneumatic Shut off valve are both SIL 2 certified and when combined into a Safety Instrumented System SIS they will meet SIL 3 performance requirements A set of sensors and actuators designed to carry out one or more safety instrumented functions Designed to protect personnel equipment and the Sale hy isi umentea System environment by reducing the likelihood or severity of an identified Safety Integrity Level emergency event Recent NFPA safety specifications mandated that safety shut off valves utilize partial stroke diagnostics manual valve reset capability and a fire Safe rating All are required to meet new IEC 61508 61511 standards These new features are required to meet the combustion safety integrity performance requirements for Safety Instrumented Functions SIF deemed necessary for the safe operation of process plants In order for a system to remain SIL compliant the safety shut off valve must Probability of Failure on Demand be tested once a year at a minimum to lower the probability of failure on demand PFD Safety Instrumented Function 32M 05004E Honeywell 9 MAXON PSCHECK PARTIAL STROKE TECHNOLOGY MAXON Series 8000 Valve description The
25. uts may be used for safety critical communications as shown in system diagram The alarms will need to be monitored Ifa red X appears on a valve or next to a valve number there is a hard major alarm If the bottom red LED on the HMI blinks there is a hard major alarm E If a yellow triangle with an appears on a valve or next to a valve number there is a soft alarm Only discrete inputs and outputs may be used for safety critical communications as shown in system diagram 20 www maxoncorp com 32M 05004E MAXON PSCHECK PARTIAL STROKE TECHNOLOGY Failure Rate Data The following table provides the failure rate data of the PSCHECK system This failure rate information can be utilized if the system Is configured to be a diagnostic If the PSCHECK is utilized as a diagnostic the following failure rates would be considered annunciation failures AD x 1 77E 05 ae eee Safety Architecture Safety Boundary Failure Notification Should any failures be detected that compromise functional safety they should be reported to MAXON Please contact MAXON customer service or your local MAXON vendor so that this issue can be addressed immediately Legal Notice MAXON or any of their affiliated entities shall not assume responsibility for the selection use operation or maintenance of any product That responsibility remains with the purchaser and end
26. w detailed information for the individual valve selected see Figure 7 Test results can also be downloaded to a Compact Flash CF drive supplied by touching the Tools icon in the upper right of the screen Instructions for downloading are provided on screen The exported information is in an easily tabulated format csv file that can be used for analysis audits and for presentation to regulatory or insurance authorities 12 www maxoncorp com 32M 05004E MAXON PSCHECK PARTIAL STROKE TECHNOLOGY FIGURE 2 ALARM HISTORY FD E CD ace CTB View alarm history list of alarms Captures all alarms the dates of the alarms and valve testing information when either a soft alert alarm or a hard failure alarm is triggered The system will track all alarm instances over the life of the valve FIGURE 3 SYSTEM SETUP PST SYSTEM SYSTEM SETUP RECTUM System Access Valve Profile edt Date of PST System Build 12 04 2013 MO DAY YEAR SIGNIN HELP Valve 1 Installation Valve 7 Installation OO 00 0000 Valve 2 Installation Valve 8 Installation OO 00 0000 Valve 3 Installation Valve 9 Installation OO 00 0000 Valve 4 Installation Valve 5 Installation Valve 6 Installation SAVE CHANGES The system build date is factory set and will be established in permanent memory During the commissioning process the customer will be required to setthe date each valve is installed This ins
27. y or a remote DCS connection It is available as a 1 2 valve system 3 5 system or 6 9 valve system PARTIAL STROKE TESTING TECHNOLOGY A process control plant in any industry is dependant on the reliability of its sub systems to keep the operation running seamlessly and without downtime In most combustion safety systems the final control element the safety shut off valve is one of the most critical elements of a complete Safety Instrumented System SIS In order for a system to remain SIL compliant the safety shut off valve must be tested once a year ata minimum to lower the probability of failure on demand PFD This historically requires a full process system shut down in order to conduct a full stroke test that completely closes and opens the valve to prove that it is functioning properly Valves are often located in hard to reach locations and local testing at the site or a full process shut down may be unrealistic The partial stroke technology is a diagnostic method to determine the status of a valve in terms of its ability to perform on demand allowing the valve to be credited with a higher SIL performance level Partial stroke testing can help detect up to 70 of dangerous undetected failures and performance issues that may prevent the valve from closing or opening MAXON s PSCHECK when combined with MAXON Series 8000 safety shut off valve helps maintain full control of a process with less downtime longer production runs and b
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