Actuators SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2 SQEx 05.2 – SQEx 14.2/SQREx 05.2 – SQREx 14.2 AUMA NORM (without controls) Manual Functional Safety Table of contents Actuators SQ.2 AUMA NORM (without controls) NOTICE for use! This document is only valid in combination with the current operation instructions enclosed with the device. Purpose of the document: The present documents informs about the actions required for using the device in safety-related systems in accordance with IEC 61508 or IEC 61511. Reference documents: ● EXIDA Report No. AUMA 13/06-74 R011, V1R0 ● Operation instructions (Assembly, operation, commissioning) for actuator Reference documents can be downloaded from the Internet (www.auma.com) or ordered directly from AUMA (refer to <Addresses>). Table of contents Page 1. 1.1. Terminology............................................................................................................................ Abbreviations and concepts 4 4 2. 2.1. 2.2. 2.3. Application and validity......................................................................................................... Range of application Standards Valid device types 6 6 6 6 3. 3.1. 3.2. 3.3. Architecture, configuration and applications...................................................................... Architecture (actuator sizing) Configuration (setting) Applications (environmental conditions) 7 7 7 7 4. 4.1. 4.2. 4.3. Safety instrumented system and safety function............................................................... Safety instrumented system including an actuator Safety function Redundant system architecture 8 8 8 8 5. 5.1. 5.2. 5.3. 5.4. 5.5. Installation, commissioning and operation......................................................................... Installation Commissioning Operation Lifetime Decommissioning 10 10 11 11 11 11 6. 6.1. 6.2. 6.2.1. 6.2.2. 6.2.3. 6.2.4. 6.3. 6.4. Tests and maintenance.......................................................................................................... Safety equipment: check Proof test (verification of safe actuator function) Preliminary tests ESD safety operation (safe operation in direction OPEN/CLOSE): check "Reaction monitoring" fault signal: check Torque switches: check Reaction monitoring/Partial Valve Stroke Test (PVST) Maintenance 12 12 12 12 12 13 13 13 13 7. 7.1. 7.2. Safety parameters.................................................................................................................. Determination of the parameters Specific parameters for actuators of SQ .2 type range 14 14 14 2 Actuators SQ.2 AUMA NORM (without controls) 8. Table of contents SIL Declaration of Conformity (example)............................................................................. 15 Index........................................................................................................................................ 17 Addresses............................................................................................................................... 18 3 Actuators SQ.2 AUMA NORM (without controls) Terminology 1. Terminology Information sources ● ● 1.1. IEC 61508-4, Functional safety of electrical/electronic/programmable electronic safety-related systems – Part 4: Definitions and abbreviations IEC 61511-1, Functional safety - Safety instrumented systems for the process industry sector – Part 1: Framework, definitions, system, hardware and software requirements Abbreviations and concepts To evaluate safety functions, the lambda values or the PFD value (Probability of Dangerous Failure on Demand) and the SFF value (Safe Failure Fraction) are the main requirements. Further figures are required to assess the individual components. These figures are explained in the table below. Table 1: Abbreviations of safety parameters Figure λS English Lambda Safe Description Number of safe failures λD Lambda Dangerous Number of dangerous failures λ DU Lambda Dangerous Undedected λ DD Lambda Dangerous Dedected Number of undetected dangerous failures Number of detected hazardous failures DC Diagnostic Coverage MTBF SFF PFDavg HFT Tproof SIL Diagnostic Coverage - ratio between the failure rate of dangerous failures detected by diagnostic tests and total rate of dangerous failures of the component or subsystem. The diagnostic coverage does not include any failures detected during proof tests. Mean Time Between Failure Mean time between two failures following one after the other Safe Failure Fraction Fraction of safe failures Average Probability of dangerous Fail- Average probability of dangerous failure on Demand ures on demand of a safety function. Hardware Failure Tolerance Ability of a functional unit to execute a required function while faults or deviations are present. HFT = n means that the function can still be safely executed for up to n faults occurring at the same time. Time for proof Interval for proof test Safety Integrity Level The international standard IEC 61508 defines 4 levels (SIL 1 through SIL 4). Safety function Safety instrumented function (SIF) Safety instrumented system (SIS) Safety-related system Function to be implemented by a safety-related system for risk reduction with the objective to achieve or maintain a safe state for the plant/equipment with respect to a specific hazardous event. Function with defined safety integrity level (SIL) to achieve functional safety. Safety instrumented system for executing a single or several safety instrumented functions. A SIS consists of sensor(s), logic system and actuator(s). A safety-related system includes all factors (hardware, software, human factors) necessary to implement one or several safety functions. Consequently failures of safety function would result in a significant increase in safety risks for people and/or the environment. A safety-related system can comprise stand-alone systems dedicated to perform a particular safety function or can be integrated into a plant. 4 Actuators SQ.2 AUMA NORM (without controls) Terminology Proof test Periodic test performed to detect dangerous hidden failures in a safety-related system so that, if necessary, a repair can restore the system to an "as new" condition or as close as practical to this condition. MTTR (Mean Time To Restoration) Mean time to restoration once a failure has occurred. Indicates the expected mean time to achieve restoration of the system. It is therefore an important parameter for system availability. The time for detecting the failure, planning tasks as well as operating resources is also included. It should be reduced to a minimum. 5 Actuators SQ.2 AUMA NORM (without controls) Application and validity 2. Application and validity 2.1. Range of application AUMA actuators with the safety function mentioned in this manual are intended for operation of industrial valves and are suitable for use in safety instrumented systems in accordance with IEC 61508 or IEC 61511. 2.2. Standards The actuators meet the following requirements: ● ● ● ● 2.3. IEC 61508, Part 2.0: Functional safety of electrical/electronic/programmable electronic safety-related systems Low Voltage Directive (2006/95/EC) Directive (EMC) (2004/108/EC) Explosion protection according to ATEX (depending on version) Valid device types The data on functional safety contained in this manual applies to the device types indicated. Table 2: Suitable device types of SQ .2 type range Type SQ 05.2 – SQ 14.2 SQR 05.2 – SQR 14.2 SQEx 05.2 – SQEx 14.2 SQREx 05.2 – SQREx 14.2 AUMA controls Without Motor Type of duty power supply S2-15 min 3-phase AC S2-30 min S4-25 % S4-50 % Control via external controls Parameters table 3 Devices may not be altered without prior written consent by AUMA. Unauthorised alterations may have a negative impacts on the devices' capability to execute a safety function. 6 Actuators SQ.2 AUMA NORM (without controls) 3. Architecture, configuration and applications 3.1. Architecture (actuator sizing) Architecture, configuration and applications For actuator architecture (actuator sizing) the maximum torques, running torques and operating times are taken into consideration. Incorrect actuator architecture can lead to device damage within the safetyrelated system! Possible consequences can be valve damage, motor overheating, contactor jamming, defective thyristors, heating up or damage to cables. → The actuator technical data must imperatively be observed when selecting the actuator. → Sufficient reserves have to be provided to ensure that actuators are capable of reliably opening or closing the valve even in the event of an accident or undervoltage. Incorrect actuator sizing may cause a dangerous failure of the safety function on demand. 3.2. Configuration (setting) Configuration (setting) of safety-relevant functions are performed as described in the operation instructions or in the present manual (functional safety). 3.3. Applications (environmental conditions) When specifying and using the actuators within safety instrumented systems, particular attention has to be paid that the permissible service conditions and the EMC requirements by the peripheral devices are met. Service conditions are indicated in the technical data sheets: Enclosure protection Corrosion protection Ambient temperature Vibration resistance If the actual ambient temperatures exceed an average of +40 °C, the lambda values have to be incremented by a safety factor. For an average temperature of +60 °C, this factor is defined at 2.5. ● ● ● ● 7 Safety instrumented system and safety function 4. Safety instrumented system and safety function 4.1. Safety instrumented system including an actuator Actuators SQ.2 AUMA NORM (without controls) Typically, a safety instrumented system including an actuator is composed of the components as shown in the figure. Figure 1: Typical safety instrumented system [1] [2] [3] [4] [5] Sensor Controls (safety PLC) Actuator Valve Distributed control system (DCS) The safety integrity level is always assigned to an overall safety instrumented system and not to an individual component. For an individual component (e.g. an actuator), safety parameters are determined. These parameters are used to assign the devices to a potential safety integrity level (SIL). The final classification of the safety instrumented system can only be made after assessing and calculating the overall system. 4.2. Safety function To determine the safety parameters, the safety function of the device (function which has to be performed in case of an emergency to operate the plant into a safe state) has to be considered. In calculating the safety parameters of the actuator, the following safety functions are taken into account: ● 4.3. ESD function (Emergency Shut Down): safe operation (in direction OPEN/CLOSE) A signal (standard: low active) causes the actuator to travel to the configured direction (OPEN/CLOSE). Redundant system architecture Besides the already described typical safety instrumented system including an actuator, safety can be increased by integrating a second, redundant valve and actuator into the safety instrumented system. The decision on the correct version depends on the entire system. 8 Actuators SQ.2 AUMA NORM (without controls) Safety instrumented system and safety function Figure 2: Redundant system with ESD for safe operation in direction CLOSE Figure 3: Redundant system with ESD for safe operation in direction OPEN 9 Installation, commissioning and operation 5. Installation, commissioning and operation Information 5.1. Actuators SQ.2 AUMA NORM (without controls) Installation and commissioning have to be documented by means of an assembly report and an inspection certificate. Installation must be carried out exclusively by suitably qualified personnel. Installation General installation tasks (assembly, electrical connection) have to be performed according to the operation instructions pertaining to the device and the enclosed order-specific wiring diagram. Figure 4: Example of wiring diagram with thermoswitches, torque and limit switches S1 S2 S3 S4 S5 Th R1 ● ● ● ● ● 10 Torque switch, closing, clockwise rotation Torque switch, opening, counterclockwise rotation Limit switch, closing, clockwise rotation Limit switch, opening, counterclockwise rotation Blinker transmitter Thermoswitches Heater For actuators in version AUMA NORM, control functions have to be implemented via external controls. To ensure the safety parameters of the SQ type range in version AUMA NORM, reaction monitoring or a Partial Valve Stroke Test (PVST) must be performed at least once a month. If the actuator does not run to the direction preset for the ESD function (irrespective of its former state) when required by the test, a fault has to be signalled. For SQ actuators in version AUMA NORM, both the reaction monitoring and the PVST function also have to be implemented within the external controls. Reaction monitoring Reaction 4 seconds after a command has been set at the latest, the blinker signal (terminals XK 49/50) should indicate a flank transition from Low “0” to High “1”. If this is not the case, a fault must be signalled. Partial Valve Stroke Test (PVST) The Partial Valve Stroke Test (PVST) is used to check the function of both actuator and valve. During this test, the function of the valve is tested by means of partial opening or closing within a defined period of time without interrupting the process. If it is not possible to operate the actuator/valve when required by the test, a fault must be signalled. Signals of the thermoswitch, the torque and limit switches as well as the signal of the blinker transmitter must be assessed within the external controls. They contain diagnostic information and are therefore imperatively required. In the event of a failure, the actuator must immediately be tested and repaired, if required. For versions with safety function ESD "Safe OPENING/CLOSING", 3-phase power supply has to be provided. Actuators SQ.2 AUMA NORM (without controls) 5.2. Installation, commissioning and operation Commissioning The operation instructions pertaining to the device must be observed for general commissioning. After commissioning, the safe actuator function must be verified. The verification must at least comprise all tests described in the <Safety equipment: check> and <Proof test (verification of safe actuator function)> chapters. 5.3. Operation Regular maintenance and device checks in the Tproof intervals as defined by the plant operator are the basis for safe operation. The operation instructions pertaining to the device must be observed for operation. The plant operator is responsible for power supply. 5.4. Lifetime Actuator lifetime is described in the technical data sheets or the operation instructions. Safety-related parameters are valid for the cycles or modulating steps specified in the technical data for typical periods of up to 10 years. After this period, the probability of failure increases. 5.5. Decommissioning When decommissioning an actuator with safety functions, the following must be observed: ● ● ● ● Impact of decommissioning on relevant devices, equipment or other work must be evaluated. Safety and warning instructions contained in the actuator operation instructions must be met. Decommissioning must be carried out exclusively by suitably qualified personnel. Decommissioning must be recorded in compliance with regular requirements. 11 Actuators SQ.2 AUMA NORM (without controls) Tests and maintenance 6. Tests and maintenance Test and maintenance tasks may only be performed by authorised personnel who have been trained on functional safety. Information 6.1. Any test/maintenance must be recorded in a test/maintenance report. Safety equipment: check All safety functions within a safety equipment must be checked for perfect functionality and safety at appropriate intervals. The intervals for safety equipment checks are to be defined by the plant operator. 6.2. Proof test (verification of safe actuator function) The proof test serves the purpose to verify the safety-related functions of the actuator. Proof tests shall reveal dangerous faults which might remain undetected until a safety function is started and consequently result in a potential danger. For test of the safety function, this function is requested by external controls. As a consequence, the actuator must perform the safety function without fault. Information The power supply of the actuator must also be considered during the proof test. Intervals: A proof test interval describes the time between two proof tests. Functionality must be checked in appropriate intervals. The intervals are to be defined by the plant operator. In any case, the safety-related functions must be checked after commissioning and following any maintenance work or repair as well as during the Tproof intervals defined in safety assessment. 6.2.1. Preliminary tests The actuator system has to be subjected to a visual inspection first. The system should be checked for outside damage and corrosion. Furthermore, the electrical and mechanical connections should be checked and the actuator be monitored for conspicuous noise. By means of run time measurement of the opening and closing procedures, further faults can be detected in case of deviation. 6.2.2. ESD safety operation (safe operation in direction OPEN/CLOSE): check Configuration The test is valid for the version with ESD function. During the ESD function test, full valve stroke or full travel of the valve should be performed. Test procedure When switching the external controls accordingly, safety operation into the desired direction must be triggered. Test sequence 1. 2. 3. 12 Operate actuator in mid-position or at sufficient distance from end positions. Execute operation command (default operation) in opposite direction of the configured ESD safety function: → For "safe operation in direction CLOSE" (ESD in direction CLOSE): Start default operation command in direction OPEN. → For "safe operation in direction OPEN" (ESD in direction OPEN): Start default operation command in direction CLOSE. Start safety operation during default operation: ➥ Safety function is correct if the actuator stops and performs a safety operation into the desired direction. ➥ No fault signal may be issued. Actuators SQ.2 AUMA NORM (without controls) 6.2.3. "Reaction monitoring" fault signal: check Configuration 6.2.4. Tests and maintenance The test is valid for the version with ESD function. Test procedure If the motor does not rotate within a defined time once a safety operation was triggered, a fault must be signalled. Test sequence 1. 2. 3. Operate actuator in mid-position or at sufficient distance from end positions. Lock motor operation to ensure manual drive remains engaged. Start ESD safety operation: ➥ 4. The fault signal is correct if a fault is signalled within 4 seconds. Once the test is complete, deactivate motor lock. Torque switches: check Torque switches are checked using the test buttons. Refer to relevant chapters in the actuator operation instructions. 6.3. Reaction monitoring/Partial Valve Stroke Test (PVST) Safety parameters indicated for SQ.2 actuators in AUMA NORM version are only valid in combination with monthly reaction monitoring or with monthly Partial Valve Stroke Tests (PVST). As described in the <Installation> chapter, the functions have to be implemented in the external controls. 6.4. Maintenance Maintenance and service tasks may only be performed by authorised personnel who have been trained on functional safety (refer to chapter 5). Once maintenance and service tasks have been finished, the functional test must be completed by a validating process of the safety function including at least the tests described in the <Safety equipment: check> and <Proof test (verification of safe actuator function)> chapters. 13 Actuators SQ.2 AUMA NORM (without controls) Safety parameters 7. Safety parameters 7.1. Determination of the parameters ● ● ● The calculation of the safety instrumented parameters is based on the indicated safety functions. Hardware assessments are based on Failure Modes, Effects and Diagnostic Analysis (FMEDA). FMEDA is a step to assess functional device safety in compliance with IEC 61508. On the basis of FMEDA, the failure rates and the fraction of safe failures of a device are determined. Experience data and data taken from the EXIDA database for mechanical components is used to deduce failure rates. The electronic failure rates as base failure rates are taken from the SIEMENS Standard SN 29500. In compliance with table 2 of IEC 61508-1, the average target PFD values for systems with low demand mode are: -2 -1 SIL 1 safety functions: ≥ 10 to < 10 -3 -2 SIL 2 safety functions: ≥ 10 to < 10 -4 -3 SIL 3 safety functions: ≥ 10 to < 10 Since actuators only represent a part of the overall safety function, the actuator PFD should not account for more than 25 % of the permissible total value (PFDavg) of a safety function. This results in the following values: Actuator PFD for SIL 2 applications: ≤ 2.50E-03 The electric actuators are classified as type A components with a hardware fault tolerance of 0. The SFF for the type A subsystem should be <60 % according to table 2 of IEC 61508-2 for SIL 1 (subsystems with a hardware fault tolerance of 0). The SFF for the type A subsystem should be between 60 % and <90 % according to table 2 of IEC 61508-2 for SIL 2 (subsystems with a hardware fault tolerance of 0). 802 hours were assumed for the MTTR. Out of these, 730 hours are used for the diagnostic test interval (e.g. PVST) and 72 hours for the MRT. ● As previously mentioned in the architecture section, safeguarding power supply and resulting calculations are the responsibility of the plant operator. The plant operator is responsible for complying with assumed MTTR. Otherwise the data of the quantitative results is no longer valid. 7.2. Specific parameters for actuators of SQ .2 type range The following parameter table provides the safety parameters for the different versions. Data records of safety instrumented parameters of all variants are available within the EXIDA test report. Table 3: SQ.2 type range in AUMA NORM version (without actuator controls) SQ 05.2 – SQ 14.2/SQR 05.2 – SQR 14.2 SQEx 05.2 – SQEx 14.2/SQREx 05.2 – SQREx 14.2 Safety function ESD Reference AUMA 13/06-74 R11 Version V1R0 0 FIT λsafe 259 FIT λ DD 14 λ DU 73 FIT DCD 77 % MTBF SFF T[proof] = 1 year 179 years 77 % PFDavg = 8.24E-04 Actuators SQ.2 AUMA NORM (without controls) 8. SIL Declaration of Conformity (example) SIL Declaration of Conformity (example) 15 SIL Declaration of Conformity (example) 16 Actuators SQ.2 AUMA NORM (without controls) Actuators SQ.2 AUMA NORM (without controls) Index Index A Actuator definition Ambient conditions Architecture 7 7 7 C Commissioning Configuration 11 7 D DC Declaration of Conformity Decommissioning Device types Diagnostic coverage (DC) 4 15 11 6 4 H HFT I Installation Interval for proof test L Lambda values Lifetime Low Demand Mode M MTBF MTTR (Mean Time To Restoration) Maintenance Mean Time Between Failures (MTBF) O Operation P PFD PFD for actuator Parameters, safety Partial Valve Stroke Test (PVST) Probability of failure Proof test R Range of application Reaction monitoring S SFF SIL Safe failure fraction (SFF) Safety function Safety instrumented function (SIF) Safety instrumented system Safety instrumented system (SIS) Safety-related system Service conditions Setting Standards T T proof Tests 4 4 4 , 14 4, 8 4 8 4 4 7 7 6 4 12 4 10 4 4 , 14 11 14 4 5 13 4 11 4 14 14 13 4 , 11 5 , 12 , 12 6 13 17 AUMA worldwide Europe AUMA Riester GmbH & Co. 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