Flowserve LPS Series Heavy-Duty Actuators User Manual

LPS Series Heavy-Duty Actuators

FCD LPS-SM-00 – 1/14

SAFETY MANUAL

Experience In Motion

LPS Series Heavy-Duty Actuators FCD LPS-SM-00 – 1/14

Summary

1 Safety Function Specification ..................................................... 3

Configuration of the Product ......................................................3

3 Service Condition Limitations (Limitation Of Use) ..................... 3

4 Expected Lifetime....................................................................... 3

5 Failure Modes and Estimated Failure Rates ................................ 4

6 Periodic Test and Maintenance Requirements

6.1 General ...........................................................................................4

6.2 Full Stroke Test .............................................................................. 4

6.3 Partial Stroke Test .......................................................................... 4

6.4 Proof Test and Periodic Maintenance ............................................ 5

7 Hardware Fault Tolerance ........................................................... 5

8 Classification..............................................................................5

9 Safe Failure Fraction .................................................................. 5

10 Mean Repair Time ...................................................................... 5

11 Systematic Capability ................................................................. 5

2
1
0 First issue / Prima

emissione

n° DESCRIPTION DATE ISSUED EMESSO APPROVED APPROVATO

01/07/2013 UT F.Pellinghelli (R&D Mngr.)

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LPS Series Heavy-Duty Actuators FCD LPS-SM-00 – 1/14

1 Safety Function Specification

The safety function used in LPS Actuator Series is defined
as follows:

Single acting actuator:
a. When an unsafe condition is detected in a plant by a

process sensor, the controller, via the control panel,
drives the Actuator to close the shut-down valve,
normally de-energizing a solenoid valve, and venting
air via the control system, OR

b. When an unsafe condition is detected in a plant by a

process sensor, the controller, via the control panel,
drives the Actuator to open the shut-down valve, normally
de-energizing a solenoid valve, and venting air via the
control system.

Double acting actuator:
a. When an unsafe condition is detected in a plant by a

process sensor, the controller, via the control panel,
drives the Actuator to close the shut-down valve,
depressurizing the OPEN chamber of the cylinder and
pressurizing the CLOSE chamber, OR

b. When an unsafe condition is detected in a plant by a

process sensor, the controller, via the control panel,
drives the Actuator to open the shut-down valve,
depressurizing the CLOSE chamber of the cylinder and
pressurizing the OPEN chamber.

The choice of the safety function to be implemented is
responsibility of the system integrator.

in the document: “PRESSURE-TORQUE CHARTS LPS
SINGLE ACTING ACTUATORS” (doc. n° DUT008-LPS-SA”,
Draft Document).

The overall dimensions of the LPS-SA actuator series, their
weight, the number of available models and all the available
constructive options are listed in the documents:
“dim-data_LPS_SA_FC”, “dim-data_LPS_SA_FO”,
“Weight SA” and “Selection table” (Draft Documents).

3 Service Condition Limitations

(Limitation of Use)
The limits of operating conditions strongly depend on the

Actuator type and on materials of construction; operating
limits of temperature and pressure are indicated in the
following table:

Operating Condition Range

Pressure

Tmin

Tmax

*MOP = Maximum Operating Pressure, as per ISO12490.

The service condition limitations (Max Rated Pressure,
Temperature range, ... ) are included on actuator label
(see below).

Design pressure = 12 barg

(MOP* depending on actuator size)

- 29°C
(-60°C with special seals)

100°C
(160°C with special seals)

2 Configuration of the Product

The LPS Actuator Series is composed by pneumatic, single
acting (spring return) LPS-SA or double acting LPS-DA
actuators designed to operate several types of quarter-turn
valves.

The LPS-SA actuators can be assembled in the ‘fail to open’
or ‘fail to close’ configurations.

Actuator design characteristics are shown on the data plate
attached to the actuator.

The LPS-SA actuator series is available in a wide torque
range. The torque ratings of this actuator series are specified

Figure 1: LPS Actuator Nameplate

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LPS Series Heavy-Duty Actuators FCD LPS-SM-00 – 1/14

4 Expected Lifetime

Actuator lifetime (for which failure rates indicated in Par. 5
are ensured) strongly depends on operating conditions and
on materials of construction.

For normal service conditions, LPS Actuators can be in good
conditions also after 25 years, with planned maintenance,
according to Par. 6.4.

5 Failure Modes and Estimated
Failure Rates

Failure

Mode

Failure on demand 6,39 E-08

Failure Modes and estimated Failure rates –
Actuators Series LPS/SA

Failure

Mode

Failure on demand 7,68 E-08

Estimated Dangerous Failure Rate

D [1/h]

Estimated Dangerous Failure Rate

D [1/h]

6.2 Full Stroke Test

The “Full Stroke Test” (“On-line”) must be performed
to satisfy the PFDAVG (average probability of failure on
demand) value.

The full test frequencies will be defined from the final
integrator, in relation to the defined SIL level to achieve.

Procedure:

• Operate the Actuator/Valve assembly for an open/close
complete cycle, with complete opening - closing of the
valve.

• Verify the Correct performing of open – close manoeuvre
(e.g. check locally, or automatically, via Logic solver, the
correct movement of the actuator/valve).

Considering the application of the above described
Full Stroke Test procedure, the “Test Coverage” can be
considered 99%.

6.3 Partial Stroke Test

The “Partial Stroke Test” (“On-line”) can be performed to
improve the PFDAVG value.

A typical partial stroke value is 15% of the stroke.
The “Partial Stroke Test” (“On line”) can be performed

to satisfy PFDAVG (average probability of failure on
demand) value.

Failure Modes and estimated Failure rates –
Actuators Series LPS/DA

NOTE: no internal diagnostics is included in the device.

6 Periodic Test and Maintenance
Requirements

6.1 General

Please consider that the information in this paragraph are
relevant only in regards of Reliability Tests; please refer to
the Document “IOM MANUAL” (“Installation, Operation and
Maintenance Manual”, doc. n° LFENIM0001) for detailed
information about product maintenance, handling and
storage.

Diagnostic tests may be made to increase the system
reliability (Full stroke or Partial stroke Test).

“On site” tests depend on Project/Plant facilities/
requirements; however, a functional test must be executed
on site, before Valve usage.

Recommended Test Interval = 1 – 3 months.

Procedure:

• Operate the Actuator/Valve assembly for in an open/close
cycle, with 15% of the stroke;

• Verify the Correct performing of partial stroke manoeuvre
(e.g. check locally, or automatically via Logic solver, or via
the PST system, the correct movement of the actuator/
valve till 15% of the stroke).

The above parameters will depend on the available partial
stroke test system.

Considering the application of the described Partial Stroke
Test procedure, the “Diagnostic Coverage” is >90 %.

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LPS Series Heavy-Duty Actuators FCD LPS-SM-00 – 1/14

6.4 Proof Test and Periodic Maintenance

We advise to perform the following checks upon each proof
test interval, complying with rules and regulations of the
final installation country:

• Visually check the entire actuator as well as the control
groups, if any.

• Ensure there are no leaks on the actuator parts under
pressure.

• Check pneumatic connections for leaks. Tighten pipe
fittings, as required.

• Check if the quick exhaust valves (if any) have been
cleaned properly.

• Check if the (hydraulic) manual override is regular.

• Check if the suction and exhaust cylinder filters have been
cleaned properly.

• Check the setting of the relief valves.

• Verify that the power fluid supply pressure value is within
the required range.

• Remove built-up dust and dirt from all actuator surfaces.

• Inspect actuator paint work for damages to ensure
continued corrosion protection. Touch-up, as required,
in accordance with the applicable paint specification.

• Operate the Actuator/Valve assembly for an open/close
complete cycle with complete closing of the valve.

• Verify the correct performing of open – close manoeuvre
(e.g. check locally, or automatically via Logic solver, the
correct movement of the actuator/valve).

8 Classification

The device is classified as Type A, according to IEC 61508-2.

9 Safe Failure Fraction

SFF (Safe Failure Fraction) = 0% without external
diagnostic tests.

SFF > 0 with external diagnostic tests, carried out according
to definition 3.8.7 of IEC 61508-4.

• SFF = 91% with Partial Stroke Test.

• SFF = 99% with Full Stroke Test.
The SFF shall be evaluated for the entire final element

sub-system.
The diagnostic test shall be performed considerably more

often than the demand of the safety function.

10 Mean Repair Time

The MRT (Mean Repair Time) of the device is 24 hours.
NOTE: The MRT is estimated considering availability of

skilled personnel for maintenance, spare parts, adequate
tools and materials on site (i.e., it encompasses the effective
time to repair and the time before the component is put back
into operation).

11 Systematic Capability

We advise to perform the following periodic maintenance:

• Replace the seals on the parts under pressure every
five years.

• Check all components subject to wear (bushings,
coupling mechanisms).

7 Hardware Fault Tolerance

The HFT (Hardware Fault Tolerance) of the device is 0.
According to Tab.6 of IEC 61511-1, the requirements

of minimum hardware fault tolerance (HFT) have to be
observed, but, as long as an assessment report, fully in
compliance with IEC 61508 part 1 to7, has been performed,
alternative fault tolerance requirements have to be
considered applicable, according to Table 2 of IEC 61508-2,
as per par. 11.4.5 of IEC 61511-1.

The systematic capability of the device is 3.
This systematic capability is guaranteed only if the user:

1. Use the device according to the instructions for use
and according to the present Manual.

2. Use the device in the appropriate environment
(limitation of use).

5

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To find your local Flowserve representative,
visit www.flowserve.com or call:
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FCD LPS-SM-00 (E) 1/14 © 2014 Flowserve Corporation.

Flowserve Corporation has established industry leadership in the design and manufacture of its products. When properly selected, this Flowserve product is designed to perform
its intended function safely during its useful life. However, the purchaser or user of Flowserve products should be aware that Flowserve products might be used in numerous
applications under a wide variety of industrial service conditions. Although Flowserve can (and often does) provide general guidelines, it cannot provide specific data and warnings
for all possible applications. The purchaser/user must therefore assume the ultimate responsibility for the proper sizing and selection, installation, operation, and maintenance of
Flowserve products. The purchaser/user should read and understand the Installation Operation Maintenance (IOM) instructions included with the product, and train its employees
and contractors in the safe use of Flowserve products in connection with the specific application.

While the information and specifications contained in this literature are believed to be accurate, they are supplied for informative purposes only and should not be considered
certified or as a guarantee of satisfactory results by reliance thereon. Nothing contained herein is to be construed as a warranty or guarantee, express or implied, regarding any
matter with respect to this product. Because Flowserve is continually improving and upgrading its product design, the specifications, dimensions and information contained herein
are subject to change without notice. Should any question arise concerning these provisions, the purchaser/user should contact Flowserve Corporation at any one of its worldwide
operations or offices.

© 2014 Flowserve Corporation, Irving, Texas, USA. Flowserve is a registered trademark of Flowserve Corporation.

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