Fisher ED Automobile Parts User Manual
Contents
1. Fisher HP and HPA Control Valves Instruction Manual D101634X012 Guidelines References Safety Integrity Level Selection Systematic Methods Including Layer of Protection Analysis ISBN 1 55617 777 1 ISA e Control System Safety Evaluation and Reliability 2nd Edition ISBN 1 55617 638 8 ISA Safety Instrumented Systems Verification Practical Probabilistic Calculations ISBN 1 55617 909 9 ISA Reference Standards Functional Safety e IEC 61508 2000 Functional safety of electrical electronic programmable electronic safety related systems ED ET EZ HP HPA Valves w 657 667 Actuator e ANSI ISA 84 00 01 2004 IEC 61511 Mod Functional Safety Safety Instrumented Systems for the Process Industry Sector Device Description Fisher ED single port valves figure 1 have cage guiding quick change trim and balanced push down to close valve plug action Valve configurations are as follows ED Globe style valve with metal to metal seating for all general applications over a wide variety of pressure drops and temperatures EAD Angle version of ED used to facilitate piping or in applications where a self draining valve is required Fisher ET single port valves figure 1 have cage guiding quick change trim and balanced push down to close valve plug action Valve configurations are as follows ET Globe style valve with metal to PTFE seating standard for all except Cavitrol III cages for stringent shu2. HPA valve must be accessible for physical inspection Table 1 Recommended Full Stroke Proof Test Bypass the safety function and take appropriate action to avoid a false trip 2 Interrupt 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 Restore the supply signal to the actuator and confirm that the normal operating state was achieved 4 Inspect the ED ET EZ HP or HPA valve and the other final control element components for any leaks visible damage or contamination Record the test results and any failures in your company s SIF inspection database 6 Remove the bypass and restore normal operation ED ET EZ HP HPA Valves w 657 667 Actuator Physical Location and Placement The Fisher ED ET EZ HP or HPA valve shall be accessible with sufficient room for the actuator pneumatic connections and 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 ED ET EZ HP or HPA valve shall be mounted in a low vibration environment If excessive vibration can be expected special precautions shall be tak
3. PFDavyc 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 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 SIL Safety Manual July 2010 Related Literature Hardware Documents 51 1 ED Fisher ED EAD and EDR Sliding Stem Control Valves Bulletin D100017X012 Fisher ED and EAD easy e Valves CL125 through CL600 Instruction Manual D100390X012 51 1 ET Fisher ET EAT and ETR Sliding Stem Control Valves Bulletin D100022X012 Fisher ET and EAT easy e Valves CL125 through CL600 Instruction Manual D100398X012 51 1 EZ Fisher EZ Sliding Stem Control Valve Bulletin D100025X012 Fisher EZ easy e Control Valve Instruction Manual D100401X012 51 2 HP Fisher HP Series Control Valves Bulletin D101635X012
4. reviewed and suitability formally assessed oOo Ooo o o Oooo Verification and Testing Eeoa connections verifedandiesied Joo Tooo Too Preumatc connection veriiedandtested J O O ooo oo o 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 e a SIL Safety Manual Note Neither Emerson Emerson Process Management nor any of their affiliated entities assume responsibility for the selection use or maintenance of any product Responsibility for the selection use and maintenance of any product remains with the purchaser and end user Fisher FIELDVUE and easy e are marks owned by one of the companies in the Emerson Process Management business division of Emerson Electric Co Emerson Process Management Emerson and the Emerson logo are trademarks and service marks of Emerson Electric Co All other marks are the property of their respective owners 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
5. SIL Safety Manual SIL Safety Manual for Fisher ED ET EZ HP or HPA Valves with 657 667 Actuator Purpose Introduction This safety manual provides information necessary to design install verify and maintain a Safety This manual provides necessary requirements for Instrumented Function SIF utilizing the Fisher ED meeting the IEC 61508 or IEC 61511 functional ET EZ HP or HPA valve with 657 667 actuator safety standards W1916 2 IL W6848 1 W8120A 1 ED or ET Valve EZ Valve HP Valve with FIELDVUE DVC6000 Digital Valve Controller Figure 1 Fisher Valve with 667 Actuator S EMERSON www Fisher com Process Management ED ET EZ HP HPA Valves w 657 667 Actuator 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 injury 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
6. 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 Neither Emerson Emerson Process Management nor any of their affiliated entities assume 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 Emerson Process Management Marshalltown lowa 50158 USA Sorocaba 18087 Brazil A Chatham Kent ME4 4QZ UK Dubai United Arab Emirates Singapore 128461 Singapore gt www Fisher com E M E RSO N 2 Uracacc iananamanti Bt Pi LALELE B T 1 ee SRBERBE eR ae te EE Ek EB Fisher Controls International LLC 2010 All Rights Reserved
7. centage 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 SIL Safety Manual July 2010 time The PVST must be performed 10 times more often than an expected demand in order for credit to be given for this test Design Verification A detailed FMEDA report is available from Emerson Process Management This report details all failure rates and failure modes as well as the expected lifetime The achieved SIL of an entire SIF design must be verified by the designer via a calculation of PFD AvG 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 HFT requirements When using an ED ET EZ HP or HPA valve ina redundant configuration a common cause factor of at least 5 should be included in the Safety Integrity calculations The failure rate data listed in the FMEDA report is only valid for the useful lifetime of an ED ET EZ HP or HPA valve 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 Int
8. egrity Level will not be achieved SIL Capability Systematic Integrity dexiaa l SIL 3 Capable Figure 2 exida SIL 3 Capable The product has met manufacturer design process requirements of SIL 3 These are intended to achieve sufficient integrity against systematic errors of design by the manufacturer A SIF designed with this product must not be used at a SIL level higher than stated without prior use justification by the end SIL Safety Manual July 2010 user or diverse technology redundancy in the design Random Integrity The ED ET EZ HP or HPA valves are classified as Type A devices according to IEC 61508 having a hardware fault tolerance of 0 The complete final element subsystem with a Fisher 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 ED ET EZ HP or HPA valve Connection of the Fisher ED ET EZ HP or HPA Valve to the SIS Logic solver The final element subsystem consisting of a positioner actuator and ED ET EZ HP or HPA valve is connected to the safety rated logic solver which is actively performing the Safety Function as well as any automatic diagnostics designed to diagno
9. en to ensure the integrity of pneumatic connectors or the vibration should be reduced using appropriate damping mounts Operation and Maintenance Suggested Proof Test The objective of proof testing is to detect failures within an ED ET EZ HP or HPA valve that are 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 an ED ET EZ HP or HPA valve is applied The proof tests must be performed more frequently than or as frequently as specified in the calculation in order to SIL Safety Manual July 2010 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 Process Management The suggested proof test consists of a full stroke of the ED ET EZ HP or HPA valve The person s performing the proof test of an ED ET EZ HP or HPA valve should be trained in SIS operations including bypass procedures valve maintenance and company Management of Change procedures No special tools are required Repair and replacement Repair pr
10. lve plug to close off the flow path through the valve body or open the flow path through the valve body The ED ET EZ HP or HPA 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 Environmental limits The designer of a SIF must check that the product is rated for use within the expected environmental limits Refer to the ED ET EZ or HP and HPA valve product bulletin for environmental limits Application limits The materials of construction of ED ET EZ HP or HPA valves are specified in the product bulletins 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 ED ET EZ HP or HPA valve is used outside of the application limits or with incompatible materials the reliability data provided becomes invalid Diagnostic Response Time The ED ET EZ HP or HPA valve does not perform any automatic diagnostic functions by itself and therefore it has no diagnostic response time 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 per
11. ocedures 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 Process Management Please contact Emerson Process Management customer service or your local Emerson Process Management service representative Status of the Document Releases Version History Version Status Date SIL Safety Manual Appendix A Start Up Checklist The following checklist may be used as a guide to Sample Startup Checklist employ the ED ET EZ HP or HPA valve in a safety This appendix provides a Sample Start up Checklist critical SIF compliant to IEC61508 for a Fisher ED ET EZ HP or HPA valve A start up checklist will provide guidance during the final control element s employment Activity Result Verified By Date Design Target Safety Integrity Level and PFDa vcg determined Correct valve mode chosen Fail closed Fail open Design decision documented SIS logic solver requirements for valve tests defined and documented 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 Maintenance instructions forprooftestreleased o o Werieationandtestpianreleased Cid S o o plementation formally
12. se potentially dangerous failures within the ED ET EZ HP or HPA valve actuator and any other final element components i e Partial Valve Stroke Test General Requirements The system s response time shall be less than process safety time The final control element ED ET EZ HP HPA Valves w 657 667 Actuator subsystem needs to be sized properly to assure that the response time is less than the required process safety time The ED ET EZ HP or HPA valve will move to its safe state in less than the required SIF s safety time under the specified conditions All SIS components including the ED ET EZ HP or HPA valve must be operational before process Start up The user shall verify that the ED ET EZ HP or HPA valve is suitable for use in safety applications Personnel performing maintenance and testing on the ED ET EZ HP or HPA valve shall be competent to do so Results from the proof tests shall be recorded and reviewed periodically The useful life of the ED ET EZ HP or HPA valve is discussed in the Failure Modes Effects and Diagnostic Analysis Report for the Fisher ED ET EZ HP or HPA valve Installation and Commissioning Installation The Fisher ED ET EZ HP or HPA 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 ED ET EZ HP or
13. toff requirements or metal to metal seating standard for Cavitrol IIl cages optional for all others for higher temperatures EAT Angle version of ET used to facilitate piping or in applications which require a self draining valve Fisher EZ valves figure 1 are globe style with integral end connections post guiding and quick change trim These valves are used in chemical or hydrocarbon processing applications or in applications that require control of nonlubricating viscous or other hard to handle fluids Fisher HP Series high pressure globe and angle valves figure 1 have metal seats cage guiding quick change trim and push down to close valve plug action HPD HPAD HPT and HPAT valves use balanced valve plugs HPS and HPAS valves use an unbalanced valve plug To provide a seal between the cage and a balanced valve plug the HPD and HPAD valve plugs use piston rings the HPT and HPAT valve plugs use a pressure assisted seal ring A Whisper Trim cage can be used with an HPD HPAD HPS HPAS HPT or HPAT valve plug A Cavitrol III cage can be used with an HPS HPAS HPT or HPAT valve plug ED ET EZ HP HPA Valves w 657 667 Actuator Designing a SIF Using Fisher ED ET EZ HP or HPA Valve 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 move the va
14. 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 SIL Safety Manual July 2010 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
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