Flowserve LPS Series Heavy-Duty Actuators User Manual

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LPS Series Heavy-Duty Actuators
FCD LPS-SM-00 – 1/14
SAFETY MANUAL
Experience In Motion
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LPS Series Heavy-Duty Actuators FCD LPS-SM-00 – 1/14
Summary
1 Safety Function Specification ..................................................... 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
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
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).
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Flowserve Limitorque Fluid-Power Product Sales
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Flowserve Limitorque Fluid-Power Product Manufacturing and Operations
via Rio Vallone 17 20883 Mezzago MB Italy Fax: +39 039 62060 213 Phone: +39 620 601 200 Email: limitorque@flowserve.com
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To find your local Flowserve representative, visit www.flowserve.com or call: USA +1 800 225 6989 International +1 972 910 0774
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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