Page 1
Instruction Manual Supplement
D104198X012
8540, 8580, 8590, Control-Disk Valves
May 2022
Safety Manual for Fisher™ 8540, 8580, 8590,
™
and Control-Disk
Purpose
This safety manual provides information necessary to design, install, verify and maintain a Safety Instrumented
Function (SIF) utilizing the Fisher 8540, 8580, 8590, or ControlDisk valve.
WARNING
This instruction manual supplement is not intended to be used as a stand-alone document. It must be used in conjunction
with the following manuals:
Fisher 8540 Rotary Valve Instruction Manual (D104709X012)
Fisher 8580 Rotary Valve Instruction Manual (D103300X012
Fisher 8590 Rotary Valve Instruction Manual (D104016X012
Fisher Control-Disk Rotary Valve Instruction Manual (D103298X012
Fisher CL600 Control-Disk Rotary Valve Instruction Manual (D104143X012
Failure to use this instruction manual supplement in conjunction with the above referenced manuals could result in
personal injury or property damage. If you have any questions regarding these instructions or need assistance in obtaining
any of these documents, contact your Emerson sales office
Valves
)
)
)
)
.
Introduction
This manual provides necessary requirements for meeting the IEC 61508 or IEC 61511 functional safety standards.
Figure 1. Fisher 8540, 8580, 8590, and Control-Disk Valves
X1846
8540 Butterfly Valve
with Bettis RPE Actuator
W9498-2
8580 Butterfly Valve
with 2052 Actuator
X0955-2
8590 Butterfly Valve
with 2052 Actuator
W9418-2
Control-Disk Valve
with 2052 Actuator
www.Fisher.com
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8540, 8580, 8590, Control-Disk Valves
May 2022
Instruction Manual Supplement
D104198X012
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
safetyrelated systems.
FailSafe State: State where valve actuator is deenergized and spring is extended.
Fail Safe: Failure that causes the valve to go to the defined failsafe 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
failsafe state).
Fail Dangerous Undetected: Failure that is dangerous and that is not being diagnosed by automatic stroke testing.
Fail Dangerous Detected: Failure that is dangerous but is detected by automatic stroke testing.
Fail Annunciation Undetected: Failure that does not cause a false trip or prevent the safety function but does cause
loss of an automatic diagnostic and is not detected by another diagnostic.
Fail Annunciation Detected: Failure that does not cause a false trip or prevent the safety function but does cause loss of
an automatic diagnostic or false diagnostic indication.
Fail No Effect: Failure of a component that is part of the safety function but that has no effect on the safety function.
Low Demand Mode: Mode, where the frequency of demands for operation made on a safetyrelated 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.
PFD
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.
: Average Probability of Failure on Demand
AVG
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 safetyrelated systems where Safety Integrity Level 4 has the highest
level of safety integrity and Safety Integrity Level 1 has the lowest.
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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).
8540, 8580, 8590, Control-Disk Valves
May 2022
Related Literature
Hardware Documents:
Bulletin:
51.6:8540, Fisher 8540 Rotary Valve: D104708X012
51.6:8580, Fisher 8580 Rotary Valve: D103299X012
51.6:8590, Fisher 8590 Butterfly Valve: D104017X012
51.3:Control-Disk, Fisher Control-Disk Rotary Valve: D103297X012 and D104025X012
Instruction Manual:
Fisher 8540 Rotary Valve: D104709X012
Fisher 8580 Rotary Valve: D103300X012
Fisher 8590 Rotary Valve: D104016X012
Fisher Control-Disk Rotary Valve: D103298X012 and D104143X012
Guidelines/References:
D Safety Integrity Level Selection – Systematic Methods Including Layer of Protection Analysis, ISBN 1556177771,
ISA
D Control System Safety Evaluation and Reliability, 2nd Edition, ISBN 1556176388, ISA
D Safety Instrumented Systems Verification, Practical Probabilistic Calculations, ISBN 1556179099, ISA
Reference Standards
Functional Safety
D IEC 61508: 2000 Functional safety of electrical/electronic/ programmable electronic safetyrelated systems
D ANSI/ISA 84.00.012004 (IEC 61511 Mod.) Functional Safety – Safety Instrumented Systems for the Process Industry
Sector
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8540, 8580, 8590, Control-Disk Valves
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Instruction Manual Supplement
D104198X012
Product Description
The Fisher 8540, 8580, 8590, and Control-Disk valves are a series of high performance butterfly valves. All four valve
types are designed to meet international standards for pressure and temperature ratings, shell thickness, and bore
diameters. They are engineered to control process fluids that can be used in a wide variety of applications and are
typically used with other interface components (valve actuator and positioner or solenoid valve) to provide a final
element subsystem for a SIF.
The 8540 valve also has a linear disk configuration with a square output shaft. The 8540 is available in sizes NPS 3 to 12
in CL150 and CL300 pressure ratings.
The 8580 valve has a linear disk configuration with a splined or square output shaft. The 8580 is available in sizes NPS 2
to 12 in CL150 and CL300 pressure ratings, and DN 50 to 300 sizes and PN 10 to 40 pressure classes.
The 8590 valve also has a linear disk configuration with splined output shaft, and is available in sizes NPS 3 to 24 in
CL600 pressure rating. The 8590 has an optional square shaft connections in sizes NPS 3 to 12, and an optional keyed
connection for sizes NPS 14 to 24.
The Control-Disk has an equal percent disk configuration with a splined shaft. The Control-Disk valve is available in
sizes NPS 2 to 12 in CL150 and CL300 pressure ratings, and DN 50 to 300 sizes in PN 10 to 40 pressure classes.
Designing an SIF Using Fisher 8540, 8580, 8590, or
Control-Disk Valve
Safety Function
When the valve's actuator is deenergized, the actuator and valve shall move to its failsafe position. Depending on
which configuration is specified fail–closed or failopen, the actuator will rotate the valve disk to close off the flow path
through the valve body or open the flow path through the valve body.
The 8540, 8580, 8590, or ControlDisk valve is intended to be part of final element subsystem as defined per IEC
61508 and the achieved SIL level of the designed function must be verified by the designer.
Pressure, Temperature, and Environmental limits
The designer of an SIF must check that the product is rated for use within the expected pressure, temperature, and
environmental limits. Refer to the 8540, 8580, 8590, or ControlDisk valve product bulletin for these limits.
Application limits
The materials of construction of 8540, 8580, 8590, or ControlDisk valves are specified in the product bulletin. A range
of materials are available for various applications. The serial card will indicate what the materials of construction are for
a given valve. It is especially important that the designer check for material compatibility considering onsite chemical
contaminants and environmental conditions. If the 8540, 8580, 8590, or ControlDisk valve is used outside of the
application limits or with incompatible materials, the reliability data provided becomes invalid.
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8540, 8580, 8590, Control-Disk Valves
May 2022
Diagnostic Response Time
The 8540, 8580, 8590, or ControlDisk 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
percentage of its normal travel without adversely affecting the flow through the valve. If any failures of this PVST are
automatically detected and annunciated, the diagnostic response time will be the PVST interval time. The PVST must
be performed 10 times more often than an expected demand in order for credit to be given for this test.
Design Verification
A detailed FMEDA report is available from Emerson. 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
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 8540, 8580, 8590, or ControlDisk valve in a redundant configuration, a common cause factor of at
least 5% should be included in the Safety Integrity calculations. This value is dependent on the level of common cause
training and maintenance in use at the end user's facility.
The failure rate data listed the FMEDA report is only valid for the useful lifetime of an 8540, 8580, 8590, or ControlDisk
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
Integrity Level will not be achieved.
considering
AVG
SIL Capability
Systematic Integrity
Figure 2. exida SIL 3 Capable
The product has met manufacturer design process requirements of IEC 61508 Safety Integrity Level 3. These are
intended to achieve sufficient integrity against systematic errors of design by the manufacturer. An SIF designed with
this product must not be used at a SIL level higher than stated without “prior use” justification by the end user or
diverse technology redundancy in the design.
Random Integrity
The 8540, 8580, 8590, and ControlDisk 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 butterfly valve as the final control
element, will need to be evaluated to determine the Safe Failure Fraction of the subsystem. If the SFF for the entire
final element subsystem is between 60% and 90%, a design can meet SIL 2 @ HFT=0.
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8540, 8580, 8590, Control-Disk Valves
May 2022
Instruction Manual Supplement
D104198X012
Safety Parameters
For detailed failure rate information refer to the Failure Modes, Effects and Diagnostic Analysis Report for the 8540,
8580, 8590, and ControlDisk valve.
Connection of the Fisher 8540, 8580, 8590, or Control-Disk Valve to the
SIS Logic-solver
The final element subsystem (consisting of a positioner, actuator, and 8540, 8580, 8590, or ControlDisk valve) is
connected to the safety rated logic solver which is actively performing the Safety Function as well as any automatic
diagnostics designed to diagnose potentially dangerous failures within the 8540, 8580, 8590, or ControlDisk 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 subsystem needs to be
sized properly to assure that the response time is less than the required process safety time. The 8540, 8580, 8590, or
ControlDisk 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 8540, 8580, 8590, or ControlDisk valve must be operational before process startup.
The user shall verify that the 8540, 8580, 8590, or ControlDisk valve is suitable for use in safety applications.
Personnel performing maintenance and testing on the 8540, 8580, 8590, or ControlDisk valve shall be competent to
do so.
Results from the proof tests shall be recorded and reviewed periodically.
The useful life of the 8540, 8580, 8590, or ControlDisk valve is discussed in the Failure Modes, Effects and Diagnostic
Analysis Report for the Fisher 8540, 8580, 8590, or ControlDisk valve.
Installation and Commissioning
Installation
The Fisher 8540, 8580, 8590, or ControlDisk valve must be installed per standard practices outlined in the appropriate
instruction manual.
The environment must be checked to verify that pressure, temperature, and environmental conditions do not exceed
the ratings.
The 8540, 8580, 8590, or ControlDisk valve must be accessible for physical inspection.
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D104198X012
8540, 8580, 8590, Control-Disk Valves
May 2022
Physical Location and Placement
The Fisher 8540, 8580, 8590, or ControlDisk valve shall be accessible with sufficient room for the actuator, pneumatic
connections, any other components of the final control element. Provisions shall be made to allow for manual proof
testing.
Pneumatic piping to the actuator shall be kept as short and straight as possible to minimize the airflow restrictions and
potential clogging. Long or kinked pneumatic tubes may also increase the valve closure time.
The 8540, 8580, 8590, or ControlDisk valve shall be mounted in a low vibration environment. If excessive vibration
can be expected special precautions shall be taken to ensure the integrity of pneumatic connectors or the vibration
should be reduced using appropriate damping mounts.
Operation and Maintenance
Suggested Proof Test
The objective of proof testing is to detect failures within an 8540, 8580, 8590, or ControlDisk 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 8540, 8580, 8590, or ControlDisk valve is applied. The proof tests must be
performed more frequently than or as frequently as specified in the calculation in order to maintain the required Safety
Integrity of the Safety Instrumented Function.
The proof test shown in table 1 is recommended. The results of the proof test should be recorded and any failures that
are detected and that compromise functional safety should be reported to Emerson. The suggested proof test consists
of a full stroke of the 8540, 8580, 8590, or ControlDisk valve.
The person(s) performing the proof test of an 8540, 8580, 8590, or ControlDisk valve should be trained in SIS
operations, including bypass procedures, valve maintenance and company Management of Change procedures. No
special tools are required.
Table 1. Recommended Full Stroke Proof Test
Step Action
1 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 FailSafe state and
3 Restore the supply/signal to the actuator and confirm that the normal operating state was achieved.
3 Inspect the 8540, 8580, 8590, or ControlDisk valve and the other final control element components for any leaks, visible damage or
4 Record the test results and any failures in your company's SIF inspection database.
5 Remove the bypass and restore normal operation.
confirm that the Safe State was achieved and within the correct time.
contamination.
Repair and replacement
Repair procedures in the appropriate valve instruction manual must be followed.
Manufacturer Notification
Any failures that are detected and that compromise functional safety should be reported to Emerson. Please contact
your Emerson sales office
.
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8540, 8580, 8590, Control-Disk Valves
May 2022
Instruction Manual Supplement
D104198X012
Appendix A
Sample Startup Checklist
This appendix provides a Sample Startup Checklist for a Fisher 8540, 8580, 8590, or ControlDisk valve. A startup
checklist will provide guidance during the final control elements emplo
Start-Up Checklist
The following checklist may be used as a guide to employ the 8540, 8580, 8590, or ControlDisk valve in a safety
critical SIF compliant to IEC61508.
# Activity Result Verified
Design
Target Safety Integrity Level and PFD
Correct valve mode chosen (Failclosed, Failopen)
Design decision documented
Pneumatic compatibility and suitability verified
SIS logic solver requirements for valve tests defined and documented
Routing of pneumatic connections determined
SIS logic solver requirements for partial stroke tests defined and
documented
Design formally reviewed and suitability formally assessed
Implementation
Physical location appropriate
Pneumatic connections appropriate and according to applicable codes
SIS logic solver valve actuation test implemented
Maintenance instructions for proof test released
Verification and test plan released
Implementation formally reviewed and suitability formally assessed
Verification and Testing
Electrical connections verified and tested
Pneumatic connection verified and tested
SIS logic solver valve actuation test verified
Safety loop function verified
Safety loop timing measured
Bypass function tested
Verification and test results formally reviewed and suitability formally
assessed
Maintenance
Tubing blockage / partial blockage tested
Safety loop function tested
determined
AVG
yment.
By Date
Neither Emerson, Emerson Automation Solutions, nor any of their affiliated entities assumes responsibility for the selection, use or maintenance
of any product. Responsibility for proper selection, use, and maintenance of any product remains solely with the purchaser and end user.
Fisher and Control-Disk are marks owned by one of the companies in the Emerson Automation Solutions business unit of Emerson Electric Co. Emerson
Automation Solutions, Emerson, and the Emerson logo are trademarks and service marks of Emerson Electric Co. All other marks are the property of their
respective owners.
The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not
to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are
governed by our terms and conditions, which are available upon request. We reserve the right to modify or improve the designs or specifications of such
products at any time without notice.
Emerson Automation Solutions
Marshalltown, Iowa 50158 USA
Sorocaba, 18087 Brazil
Cernay, 68700 France
Dubai, United Arab Emirates
Singapore 128461 Singapore
www.Fisher.com
8
E 2012, 2022 Fisher Controls International LLC. All rights reserved.
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