GE Masoneilan SVI II ESD Installation And Maintenance Manual
GE Oil & Gas
GE Data Classification: Public
Masoneilan*
SVI* II ESD
Smart Valve Interface with SIL3
Emergency Shutdown PST Controller
Installation and Maintenance Manual
About this Guide
This instruction manual covers the following instruments and approved software:
Through SVI II ESD -6
with Firmware version 3.1.2 or greater
with ValVue* ESD version 1.0 or greater
with Handheld HART
®
Communicator with DD published for SVI II ESD
Masoneilan* Device Type 203 or 0xCB
with PRM PLUG-IN ValVue ESD version 1.0 or greater
The information contained in this manual, in whole or part, shall not be transcribed or copied without GE’s written permission.
In no case does this manual guarantee the merchantability of the positioner or the software or its adaptability to a specific
client needs.
Please report any errors or questions about the information in this manual to your local supplier or visit www.geoilandgas.com/valves.
U. S. Patent No. 6,957,127, Additional Patents Pending
DISCLAIMER
THESE INSTRUCTIONS PROVIDE THE CUSTOMER/OPERATOR WITH IMPORTANT PROJECT-SPECIFIC REFERENCE INFORMATION IN ADDITION TO THE CUSTOMER/OPERATOR’S NORMAL OPERATION AND MAINTENANCE PROCEDURES. SINCE
OPERATION AND MAINTENANCE PHILOSOPHIES VARY, GE (GENERAL ELECTRIC COMPANY AND ITS SUBSIDIARIES AND
AFFILIATES) DOES NOT ATTEMPT TO DICTATE SPECIFIC PROCEDURES, BUT TO PROVIDE BASIC LIMITATIONS AND
REQUIREMENTS CREATED BY THE TYPE OF EQUIPMENT PROVIDED.
THESE INSTRUCTIONS ASSUME THAT OPERATORS ALREADY HAVE A GENERAL UNDERSTANDING OF THE REQUIREMENTS
FOR SAFE OPERATION OF MECHANICAL AND ELECTRICAL EQUIPMENT IN POTENTIALLY HAZARDOUS ENVIRONMENTS.
THEREFORE, THESE INSTRUCTIONS SHOULD BE INTERPRETED AND APPLIED IN CONJUNCTION WITH THE SAFETY RULES
AND REGULATIONS APPLICABLE AT THE SITE AND THE PARTICULAR REQUIREMENTS FOR OPERATION OF OTHER EQUIPMENT AT THE SITE.
THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN EQUIPMENT NOR TO PROVIDE FOR
EVERY POSSIBLE CONTINGENCY TO BE MET IN CONNECTION WITH INSTALLATION, OPERATION OR MAINTENANCE.
SHOULD FURTHER INFORMATION BE DESIRED OR SHOULD PARTICULAR PROBLEMS ARISE WHICH ARE NOT COVERED
SUFFICIENTLY FOR THE CUSTOMER/OPERATOR'S PURPOSES THE MATTER SHOULD BE REFERRED TO GE.
THE RIGHTS, OBLIGATIONS AND LIABILITIES OF GE AND THE CUSTOMER/OPERATOR ARE STRICTLY LIMITED TO THOSE
EXPRESSLY PROVIDED IN THE CONTRACT RELATING TO THE SUPPLY OF THE EQUIPMENT. NO ADDITIONAL REPRESENTATIONS OR WARRANTIES BY GE REGARDING THE EQUIPMENT OR ITS USE ARE GIVEN OR IMPLIED BY THE ISSUE OF THESE
INSTRUCTIONS.
THESE INSTRUCTIONS ARE FURNISHED TO THE CUSTOMER/OPERATOR SOLELY TO ASSIST IN THE INSTALLATION, TESTING, OPERATION, AND/OR MAINTENANCE OF THE EQUIPMENT DESCRIBED. THIS DOCUMENT SHALL NOT BE REPRODUCED IN WHOLE OR IN PART TO ANY THIRD PARTY WITHOUT THE WRITTEN APPROVAL OF GE.
Copyright
All information contained herein is believed to be accurate at the time of publication and is subject to change
without notice.
Copyright 2016 by General Electric Company. All rights reserved. PN 011523-561 Rev. F
Document Changes
Version/Date Changes
B/4-2011 Removed non-installation software-related issues (See help). Rearranged book. Updated installation.
Amended Switches description.
Registration section updated to GE logo software.
C/3-2013 Removed references to double-acting.
D/9-2013 Changed the Simplified Switch diagram in Output Switches section and added a cross reference to it
in the install section. Added Cautions about Position Low and Upper Limits.
Added text about the 4-20 retransmit galvanic isolation.
E/2-2014 Updated load description for optional switches.
F/4-2016 Updated the Installation section and the Fault Matrix.
Modified connection drawings for intrinsically safe in Appendices B and C.
Made changes to Wiring Guidelines for Position retransmit.
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Contents
1. Safety Information ...................................................................................................................................................................... 17
Introduction ................................................................................................................................................................................. 17
Terms and Abbreviations....................................................................................................................................................... 17
Acronyms.............................................................................................................................................................................. 18
Safety Symbols........................................................................................................................................................................... 19
Related Literature ..................................................................................................................................................................... 19
Reference Standards............................................................................................................................................................... 20
SVI II ESD Device Description ............................................................................................................................................... 20
Designing an SIF Using an SVI II ESD ............................................................................................................................... 21
Safety Function.................................................................................................................................................................. 21
Environmental Limits....................................................................................................................................................... 21
Design Verification ........................................................................................................................................................... 22
SIL Capability....................................................................................................................................................................... 22
Connecting the SVI II ESD to the SIS Logic Solver.............................................................................................. 23
General Requirements.................................................................................................................................................... 24
Installation.................................................................................................................................................................................... 25
SVI II ESD Installation Configurations ...................................................................................................................... 25
Physical Location and Placement Guidelines...................................................................................................... 25
Pneumatic Connections................................................................................................................................................. 25
Electrical Connections .................................................................................................................................................... 25
Operation, Setup, Commissioning..................................................................................................................................... 25
Maintenance................................................................................................................................................................................ 25
Diagnostics................................................................................................................................................................................... 25
PST............................................................................................................................................................................................ 25
SVI II ESD Product Safety ....................................................................................................................................................... 27
2. Introduction .................................................................................................................................................................................... 29
ValVue ESD Overview .............................................................................................................................................................. 29
ValVue ESD Software............................................................................................................................................................... 30
ValVue ESD Trial Version................................................................................................................................................ 30
System Requirements..................................................................................................................................................... 31
Available Models................................................................................................................................................................ 32
About This Manual.................................................................................................................................................................... 32
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3. Software Installation and Setup ........................................................................................................................................... 33
Install ValVue ESD and PRM Plug-In.................................................................................................................................. 33
Installing ValVue ESD Software...................................................................................................................................33
Installing the Yokogawa® PRM Plug-In ..................................................................................................................37
Registering ValVue ESD...........................................................................................................................................................49
Entering Software Keys ..................................................................................................................................................53
4. Installation and Setup ................................................................................................................................................................ 55
Overview ........................................................................................................................................................................................55
SVI II ESD Dimensions and Weights.......................................................................................................................... 56
Pre-Installation Issues .............................................................................................................................................................57
Storage................................................................................................................................................................................... 57
Unpacking.............................................................................................................................................................................57
Installation ....................................................................................................................................................................................57
Physical Location and Placement Guidelines ......................................................................................................58
Mounting the SVI II ESD on Rotary Valves.............................................................................................................. 61
Travel Sensor Alignment ................................................................................................................................................63
Mounting the SVI II ESD with NAMUR Kits..............................................................................................................64
Mounting the SVI II ESD on Reciprocating Valves .............................................................................................. 66
Checking the Magnet ......................................................................................................................................................69
Using ValVue ESD to Check Magnet Position .......................................................................................................69
Checking Actuator, Linkages, or Rotary Adapter ...............................................................................................70
Connecting the Tubing and Air Supply.................................................................................................................... 71
Checking the Air Supply..................................................................................................................................................73
Wiring the SVI II ESD......................................................................................................................................................... 73
Powering Up the SVI II ESD ........................................................................................................................................... 78
Making Connections to the Terminal Board .........................................................................................................83
SVI II ESD Maintenance ...........................................................................................................................................................84
Repair and Replacement ............................................................................................................................................... 84
Factory Notification..........................................................................................................................................................84
Display Cover Removal and Installation................................................................................................................. 85
5. Configuration and Calibration ............................................................................................................................................... 87
Overview.......................................................................................................................................................................................87
SVI II ESD Setup........................................................................................................................................................................... 87
Configuration...............................................................................................................................................................................88
Configuration with Pushbutton Display ..........................................................................................................................88
Calibration with Pushbutton Display................................................................................................................................91
Calibration using Auto Tune.........................................................................................................................................92
Correct for Over Travel.................................................................................................................................................... 92
Adjust Input Signal Range .............................................................................................................................................93
Configuring with ValVue ESD ...............................................................................................................................................94
Starting ValVue ESD/ESDVue .......................................................................................................................................94
Check-out with a HART® Handheld Communicator ................................................................................................ 95
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6. Using the Digital Interfaces ..................................................................................................................................................... 97
Overview........................................................................................................................................................................................97
Local Display and Pushbuttons .................................................................................................................................. 97
HART® Handheld Communicator ............................................................................................................................. 97
ValVue ESD ........................................................................................................................................................................... 98
Pushbuttons and Local Display .......................................................................................................................................... 98
Accessing Pushbuttons ............................................................................................................................................... 100
Pushbutton Locks and Configuration-Lock Jumper...................................................................................... 100
Display Menus.......................................................................................................................................................................... 102
NORMAL Operating Mode and MANUAL Mode Menus................................................................................. 102
Configure Menu............................................................................................................................................................... 103
Calibration Menu ............................................................................................................................................................ 105
PST Configuration Menu ............................................................................................................................................. 106
VIEW DATA Menu............................................................................................................................................................ 107
PST CONF (VIEW DATA) Menu ................................................................................................................................... 109
VIEW ERR............................................................................................................................................................................ 110
Clear Error.................................................................................................................................................................................. 111
FAILSAFE Mode................................................................................................................................................................ 111
Handheld Communicator................................................................................................................................................... 112
ValVue ESD ................................................................................................................................................................................ 113
7. Partial Stroke Testing .............................................................................................................................................................. 115
Overview..................................................................................................................................................................................... 115
Partial Stroke Test Diagnostics ........................................................................................................................................ 116
PST Configuration................................................................................................................................................................... 116
PST Configuration with Display Menu................................................................................................................... 116
PST Setup with ValVue ESD................................................................................................................................................ 118
PST Data from ESDVue ................................................................................................................................................ 118
8. Operation and Maintenance ............................................................................................................................................... 121
Operational Overview........................................................................................................................................................... 121
SVI II ESD Applications and Designated Safety Function Activation...................................................... 122
Additional Features ....................................................................................................................................................... 123
Physical and Operational Description .......................................................................................................................... 124
SVI II ESD Components......................................................................................................................................................... 125
Electronics Module ........................................................................................................................................................ 125
Output Switches.............................................................................................................................................................. 127
Pneumatic Module......................................................................................................................................................... 130
Optional Display and Pushbuttons ........................................................................................................................ 131
SVI II ESD Maintenance........................................................................................................................................................ 131
Repair and Replacement............................................................................................................................................ 131
Factory Notification....................................................................................................................................................... 132
Display Cover Removal and Installation.............................................................................................................. 132
Upgrading Firmware............................................................................................................................................................. 134
Tools Required ................................................................................................................................................................. 134
Installing Firmware Upgrade.................................................................................................................................... 134
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9. Troubleshooting ......................................................................................................................................................................... 135
Overview ..................................................................................................................................................................................... 135
Internal Diagnostics............................................................................................................................................................... 135
FAILSAFE Mode ............................................................................................................................................................... 136
Accessing Diagnostic Information.................................................................................................................................. 136
Error Messages on LCD........................................................................................................................................................ 137
Positioner Fault Messages ......................................................................................................................................... 137
Return to Normal Operation...................................................................................................................................... 137
VIEW ERR Diagnostics Messages ............................................................................................................................ 138
Fault Matrix................................................................................................................................................................................ 139
Troubleshooting with ESDVue .......................................................................................................................................... 153
Appendix A. Specifications and References .......................................................................................................................155
Physical and Operational Specifications ..................................................................................................................... 155
Models and Applications ..................................................................................................................................................... 161
Hazardous Area Certifications ................................................................................................................................. 161
SVI II ESD Models............................................................................................................................................................. 164
Appendix B. Installing an SVI II ESD in a Natural Gas Environment ......................................................................... 165
Remote Actuator Vent Gas Connection ....................................................................................................................... 167
Remote Gas Piping......................................................................................................................................................... 167
Single Acting Installation............................................................................................................................................. 167
Appendix C. HART® Wiring Configurations ........................................................................................................................169
Overview ..................................................................................................................................................................................... 169
System Connections.............................................................................................................................................................. 169
HART® Wiring Guidelines ................................................................................................................................................... 171
SVI II ESD Setups ............................................................................................................................................................. 172
Grounding Practices...................................................................................................................................................... 174
Compliance Voltage in Single Drop Current Mode ......................................................................................... 175
Wire Size and Conduit .................................................................................................................................................. 176
HART® Physical Layer Compliance of the Control System................................................................................. 177
Impedance Constraints ............................................................................................................................................... 177
Noise Constraints ........................................................................................................................................................... 177
Cabling and Interconnection Requirements...................................................................................................... 178
Capacitance vs. Length of Cable for HART®..................................................................................................... 178
HART® Filter Required for Certain Control System Output Circuits ....................................................... 178
Split Range Applications...................................................................................................................................................... 179
Setting Loop Addresses for Split Range Systems............................................................................................ 179
Multiple Output Circuit Control System................................................................................................................ 181
Isolators .............................................................................................................................................................................. 182
Supplemental Power Supply ..................................................................................................................................... 184
Verify Wiring and Connections................................................................................................................................. 184
Required Practices for Explosion Proof Installations ............................................................................................. 186
Clarification of Terminology ...................................................................................................................................... 186
Recommended Practice for Severe or Humid Environments.................................................................... 186
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HART® DCV Setup.................................................................................................................................................................. 187
HART® Module Positions............................................................................................................................................ 187
Field Wiring ....................................................................................................................................................................... 187
Appendix D. HART® Communications with Intrinsic Safety ........................................................................................ 189
Overview..................................................................................................................................................................................... 189
HART® Barrier Compliance ............................................................................................................................................... 190
Output Channel Isolation.................................................................................................................................................... 191
HART® Filter Requirements............................................................................................................................................... 191
Modem and Computer Use in Intrinsically Safe Circuits...................................................................................... 193
MACTek® Intrinsically Safe modem, Model 010005...................................................................................... 193
MACTek® Warning ....................................................................................................................................................... 193
Use of Hand-held Communicators In Intrinsically Safe Circuits .............................................................. 193
Appendix E. Air to Open and Air to Close Actuators ........................................................................................................ 195
Actuator Action........................................................................................................................................................................ 195
Appendix F. Air Supply Requirements .................................................................................................................................... 199
Appendix G. Adjusting Speed of Response .......................................................................................................................... 201
Appendix H. Glossary ..................................................................................................................................................................... 203
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List of Figures
1 SVI II ESD................................................................................................................................................................................ 29
2 ValVue ESD CD Browser ................................................................................................................................................. 33
3 Software Choice.................................................................................................................................................................34
4 Install Shield Wizard......................................................................................................................................................... 34
5 License Agreement...........................................................................................................................................................35
6 Choose Destination Location.......................................................................................................................................35
7 Ready to Install................................................................................................................................................................... 36
8 ValVue ESD CD Browser ................................................................................................................................................. 37
9 Software Choice.................................................................................................................................................................38
10 PRM Plug-In Main Screen............................................................................................................................................... 38
11 PRM Central Server License Agreement................................................................................................................. 39
12 PRM Central Server Destination Folder...................................................................................................................39
13 PRM Central Server Database Directory Destination Folder......................................................................... 40
14 Ready to Install...................................................................................................................................................................41
15 PRM Central Server Dialog ............................................................................................................................................ 41
16 PRM Central Server Dialog II......................................................................................................................................... 41
17 PRM Central Server Dialog III ....................................................................................................................................... 42
18 Database Directory Reminder.....................................................................................................................................42
19 ValVue ESD CD Browser ................................................................................................................................................. 43
20 Software Choice................................................................................................................................................................. 44
21 PRM Plug-In Main Screen............................................................................................................................................... 44
22 Install Shield PRM Plug-In .............................................................................................................................................. 45
23 PRM Plug-In License Agreement................................................................................................................................ 45
24 PRM Plug-In Destination Folder.................................................................................................................................. 46
25 Choose Folder .....................................................................................................................................................................46
26 PRM Plug-In Client Database Location Destination Folder............................................................................ 47
27 Choose Folder .....................................................................................................................................................................47
28 Ready to Install................................................................................................................................................................... 48
29 Owner and Product Key Registration Window....................................................................................................49
30 Applying Owner and Product Key Information ................................................................................................... 50
31 Software and Mux Key Window .................................................................................................................................50
32 Launching Registration Window................................................................................................................................51
33 Registration Window .......................................................................................................................................................51
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34 Save Registration Information.....................................................................................................................................52
35 Registration File Saved Dialog.....................................................................................................................................52
36 Registration Email Sent Dialog ....................................................................................................................................53
37 Entering Software Key.....................................................................................................................................................53
38 Entering Mux Unlock Key ...............................................................................................................................................54
39 Successful Registration Message...............................................................................................................................54
40 SVI II ESD Exploded View ................................................................................................................................................55
41 SVI II ESD Dimensions ......................................................................................................................................................56
42 Camflex with Mounting Bracket (Side View)..........................................................................................................61
43 Namur 20/30 mm Mounting Kit..................................................................................................................................64
44 Namur 50 mm Mounting Kit.........................................................................................................................................65
45 Magnet Holder for Reciprocating Valves................................................................................................................66
46 Reciprocating Valve Mounting Bracket...................................................................................................................66
47 Reciprocating Linkage.....................................................................................................................................................67
48 Lever for Model 87/88 Multispring Actuator .........................................................................................................68
49 ValVue ESD for Checking Magnet Position ............................................................................................................70
50 Air Ports on Single Acting PST Controller ................................................................................................................72
51 Analog Safety Demand (ASD) Configuration.........................................................................................................75
52 Discrete Safety Demand (DSD) Configuration ......................................................................................................75
53 Analog with Discrete Safety Demand (A/DSD) Configuration.......................................................................76
54 Connections to ASD Electronics Module (via Terminal Board)......................................................................81
55 Connections to DSD Electronics Module (via Terminal Board) .....................................................................82
56 Connections to A/DSD Electronics Module (via Terminal Board).................................................................82
57 SVI II ESD Pneumatic and Display Covers ..............................................................................................................85
58 Configuration Pushbutton Guide................................................................................................................................90
59 ValVue ESD Icon .................................................................................................................................................................94
60 SVI II ESD HART® Communicator Connections...................................................................................................95
61 SVI II ESD Display................................................................................................................................................................98
62 NORMAL Operation and MANUAL Menu Structures.......................................................................................102
63 CONFIGure Menu ............................................................................................................................................................103
64 CALIBration Menu...........................................................................................................................................................105
65 PST CONFiguration Menu............................................................................................................................................106
66 VIEW DATA Menu ............................................................................................................................................................108
67 PST CONFiguration (VIEW DATA) Menu.................................................................................................................110
68 View Err Menu...................................................................................................................................................................110
69 FAILSAFE Menu ................................................................................................................................................................112
70 PST Configuration Pushbutton Menu ....................................................................................................................117
71 PST Diagnostic Graph Example................................................................................................................................118
72 PST Benefits.......................................................................................................................................................................119
73 Block Diagram with I/P Converter and Pressure Sensor.............................................................................. 124
74 Simplified Switch Installation Drawing: Correct Configuration .................................................................128
75 Simplified Switch Installation Drawing: Configuration Not Allowed .......................................................128
76 Pneumatic Module with Single Acting Relay......................................................................................................130
77 SVI II ESD Pneumatic and Display Covers ...........................................................................................................132
78 SVI II ESD Model Numbering...................................................................................................
...................................164
81 General Purpose and Explosion Proof Installation..........................................................................................173
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82 Intrinsically Safe Installation ..................................................................................................................................... 174
83 Selecting Set Options - Tools Menu on Connected Devices Screen ....................................................... 180
84 Selecting Set Options - Right Click on Connected Devices Screen ......................................................... 180
85 ValVue ESD Setup Options for Multidrop............................................................................................................. 181
86 Split Range with Isolator ............................................................................................................................................. 183
87 Split Range with Supplemental Power Supply - Non-Hazardous............................................................ 185
88 HART® Device in DCV Application.......................................................................................................................... 187
89 Intrinsically Safe Installation with Zener Barrier and HART® Filter......................................................... 190
90 Intrinsically Safe Installation with Galvanic Isolator ...................................................................................... 192
91 ATO and ATC Action with Linear Positioner Characteristics....................................................................... 196
92 ATO and ATC Action in Percentage of Positioner Characteristics............................................................ 197
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List of Tables
1 Proof Test Steps .................................................................................................................................................................26
2 ValVue Software Installation Sizes............................................................................................................................31
3 Software Requirements.................................................................................................................................................. 31
4 SVI II ESD Installation Steps ..........................................................................................................................................57
5 Travel Sensor Alignment................................................................................................................................................ 63
6 Reciprocating Valve Mounting Hole and Turnbuckle Length....................................................................... 68
7 Pneumatic Connections/Air Supply Requirements ........................................................................................... 71
8 SVI II ESD Models and Functionality .........................................................................................................................81
9 VIEWDATA Settings...........................................................................................................................................................89
10 Pushbutton Display Menus...........................................................................................................................................99
11 Pushbutton Lock Security Level............................................................................................................................... 100
12 SVI II ESD Fault Matrix .................................................................................................................................................. 139
13 Environmental Specifications................................................................................................................................... 155
14 Safety Rated Inputs....................................................................................................................................................... 156
15 Operational Specifications......................................................................................................................................... 156
16 Input Signal, Power, and Display Specifications .............................................................................................. 157
17 Construction Material Specifications .................................................................................................................... 157
18 System Connectivity...................................................................................................................................................... 158
19 Pneumatics Single Acting Standard Flow........................................................................................................... 158
20 Control Valve Mounting System .............................................................................................................................. 159
21 ESD and Diagnostic Capabilities ............................................................................................................................. 159
22 Device ID Information .................................................................................................................................................. 160
23 Burst Mode Data Return ............................................................................................................................................. 160
24 SVI II ESD Model Features........................................................................................................................................... 161
25 SVI II ESD Physical Attributes .................................................................................................................................... 161
27 CSA International Certifications............................................................................................................................... 162
28 FM Approvals.................................................................................................................................................................... 162
29 Temperature Class......................................................................................................................................................... 162
26 ATEX Approvals................................................................................................................................................................ 162
30 Immunity Performance................................................................................................................................................ 163
31 Radiation Performance ............................................................................................................................................... 163
32 Compliance Voltage for Single Channel Zener with 22 AWG Cable Installation .............................. 175
33 Compliance Voltage for Galvanic Isolator with 22 AWG Cable Installation ....................................... 175
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34 Compliance Voltage for No Barrier with HART® Filter and Resistor and 18 AWG Cable .............176
35 Supplemental Voltage for Split Range..................................................................................................................184
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1. Safety Information
Introduction
This section provides information necessary to design, install, verify and maintain a Safety
Instrumented Function (SIF) utilizing a Masoneilan Smart Valve Interface, SVI II ESD. This manual
provides necessary requirements for meeting the IEC 61508 or IEC 61511 functional safety
standards.
Terms and Abbreviations
The following terms and abbreviations are related to safety functions of the SVI II ESD and are
used throughout this document.
Safety Freedom from unacceptable risk of harm.
Functional
Safety
Basic Safety The equipment must be designed and manufactured such that it protects
Safety
Assessment
Fail-Safe State State where the SVI II ESD is de-energized and has exhausted Actuator 1 in a sin-
Fail Safe Failure that causes the valve to go to the defined fail-safe state without a
Fail Dangerous Failure that does not respond to a demand from the process (i.e. being unable to
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.
against risk of damage 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.
The investigation to arrive at a judgment - based on evidence - of the safety
achieved by safety-related systems.
gle acting configuration or has caused Actuator 1 to be at an equal or lower
pressure than Actuator 2 in a dual acting configuration.
demand from the process.
go to the defined fail-safe state).
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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
Fail Annunciation Detected Failure that does not cause a false trip or prevent the safety function
Fail No Effect Failure of a component that is part of the safety function but that has
Low Demand Mode Mode, where the frequency of demands for operation made on a
Acronyms
FMEDA Failure Modes, Effects and Diagnostic Analysis
HFT Hardware Fault Tolerance
MOC Management of Change. These are specific procedures often done
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.
but does cause loss of an automatic diagnostic or false diagnostic
indication.
no effect on the safety function.
safety-related system is no greater than twice the proof test frequency.
The following acronyms are related to safety functions of the SVI II ESD and are used
throughout this document.
when performing any work activities in compliance with government
regulatory authorities.
PFDavg Average Probability of Failure on Demand
PST Partial Stroke Test, a test used to detect failure modes in the posi-
tioner, actuator, and valve assembly.
SFF Safe Failure Fraction, the fraction of the overall failure rate of a
device that results in either a safe fault or an 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).
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Safety Symbols
Conventions used in this manual are as follows:
Italicized letters are used when referencing a term used in the program display
window.
Italics is used for emphasis on important items.
Fields where data is entered or user-entered data is italicized.
Actions performed on buttons, checkboxes, etc. appear bolded. For example: Click
Done.
NOTE Indicates important facts and conditions.
CAUTION Indicates a potentially hazardous situation, which if not avoided
may result in property damage or data loss.
WARNING Indicates a potentially hazardous situation, which if not avoided
Related Literature
Listed below are documents related to the SVI II ESD.
TUV Certificate No. SAS0016/07, Vers. 1.0
Hardware Document SVI II ESD Quick Start Guide, MN-SVI-ESD_QSG-GEA19520
Guidelines/
References
may result in death or serious injury.
SVI II ESD SIL 3 Partial Stroke Test Device, BW500-ESD
Safety Integrity Level Selection – Systematic Methods
Including Layer of Protection Analysis, ISBN 1-55617-777-1,
ISA
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
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Masoneilan SVI II ESD Installation and Maintenance Manual =| 19
Reference Standards
Listed below are Functional Safety reference standards related to the SVI II ESD:
IEC 61508: 2000 – Functional safety of electrical/electronic/programmable electronic
safety-related systems
ANSI/ISA 84.00.01-2004 (IEC 61511 Mod.) Functional Safety – Safety Instrumented
Systems for the Process Industry Sector
SVI II ESD Device Description
An ESD valve is a valve that operates to ensure that the process is brought to its safe state.
During normal operation, these ESD valves are typically energized to stay open (ATO). In case
of an unsafe situation, the ESD valve is de-energized by the Safety System. The SVI II ESD
device performs this shutdown function for Safety Instrumented Functions (SIF) that require
field devices to be certified for safety related applications according to IEC61508 as certified
by TUV for use up to SIL3 with an HFT of 0 in low demand applications. The built-in
microprocessor is used for valve diagnostics only. The microprocessor has no direct role in
performing the designated safety function therefore the SVI II ESD is considered a Type A
device.
The SVI II ESD is a valve controller which mounts on a pneumatically actuated valve assembly.
Its role is to position an emergency shutdown valve to 0% or 100% with a PFDavg in
accordance with IEC61508 for SIL3 application.
Because of its capability of monitoring data from its embedded sensors, the SVI II ESD is
capable of validating the health of its integral components. In addition, due to the ability of
partially stroking, the ESD valve while in normal operations (energized to stay open - ATO); it
becomes possible to validate the health of the valve and actuator assembly. Configurable
time based testing of the ESD valve reduces the PFDavg by detecting dangerous failures.
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Designing an SIF Using an SVI II ESD
The following must be taken into consideration when designing a SIF (Safety Instrumented
Function) using the SVI II ESD:
Safety Function
Environmental Limits
Design Verification
SIL Capability
Connecting the SVI II ESD to the SIS Logic-Solver
General Requirements
Safety Function
When de-energized, the SVI II ESD moves to its fail-safe position. For a single-acting PST
controller the safe state is when the port Actuator 1 is exhausted to a pressure less than 1
PSIG (0.069 bar, 6.9 kPa). The valve actuation must automatically move the valve to the safe
state when the digital valve controller falls in safe state.
The SVI II ESD is intended to be part of final element subsystem, as per IEC 61508, and the
achieved SIL level of the function must be verified by the function designer.
Environmental Limits
The designer of a SIF must check that the product is rated for use within the environmental
limits as stated in Table 13 on page 155.
Application Limits
Listed below are the application limits for the SVI II ESD installed in a SIF:
The application of the SVI II ESD is limited for SIF where the safe state is the
de-energized state (shutdown) of the valve. The PST Controller can be operated with
either one of two control signals: 4 - 20 mA or 0 - 24 VDC.
With a 4 - 20 mA control signal, normal operation is with a 20 mA current loop signal to
the PST controller. A shutdown command is issued by bringing the current to 5.6 mA or
lower.
With a 0 - 24 VDC control signal, normal operation is with a 24 VDC signal applied to
the PST controller. A shutdown command is issued by opening the loop or bringing the
control signal to 3 VDC or lower.
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Masoneilan SVI II ESD Installation and Maintenance Manual =| 21
Design Verification
The following describes the design verification criteria for the SIF and the SVI II ESD:
A detailed Failure Mode, Effects, and Diagnostics Analysis (FMEDA) report is available
from the factory. This report details all failure rates and failure modes as well as the
expected lifetime.
The achieved Safety Integrity Level (SIL) of an entire Safety Instrumented Function (SIF)
design must be verified by the designer by means of PFDavg calculation, considering
redundant architectures, proof test interval, proof test effectiveness, any automatic
diagnostics, average repair time and specific failure rates of all products included in
the SIF. Each subsystem must be checked to assure compliance with minimum
hardware fault tolerance (HFT) requirements. The exida exSILentia
recommended for this purpose as it contains accurate models for the SVI II ESD and
related failure rates.
When using an SVI II ESD in a redundant configuration, include a common cause factor
of 5% in safety integrity calculations.
The failure rate data listed in the FMEDA report is valid only for the useful life time of an
SVI II ESD. The failure rates sometimes increase after this time period. Reliability
calculations based upon the data listed in the FMEDA report for mission times beyond
the lifetime can yield results too optimistic, i.e. the calculated Safety Integrity Level will
not be achieved.
®
tool is
SIL Capability
The SVI II ESD meets SIL 3 requirements as outlined below.
Systematic Integrity
The product has met manufacturer design process requirements of Safety Integrity Level (SIL)
3. These are intended to achieve sufficient integrity against systematic errors of design by the
manufacturer. A Safety Instrumented Function (SIF) designed with this product must not be
used at a SIL level higher than the statement without prior use justification by end user or
diverse redundant technology in the design.
Random Integrity
The SVI II ESD’s safety critical function is maintained by a Type A Device. Therefore based upon
the SFF > 90%, when the SVI II ESD is used as the sole component in a final element
subassembly, a design can meet SIL 3 @ HFT=0.
When the final element assembly consists of many components (SVI II ESD, quick exhaust
valve, actuator, isolation valve, etc.) the SIL must be verified for the entire assembly taking into
consideration failure rate of each component. This analysis must account for any hardware
fault tolerance and architecture constraints.
22 | =GE Oil & Gas
© 2016 General Electric Company. All rights reserved.
Safety Parameters
For detailed failure rate information refer to the Failure Modes, Effects and Diagnostic Analysis
Report for the SVI II ESD available from the factory.
SIL Certification
This product guarantees to respond to commanded trip signal with a PFD in accordance to
IEC61508 SIL3
Capable of partially stroking the valve using one of the following initiation methods, that will
be IEC61508 SIL2 certified:
Built-In Scheduler within the SVI II ESD
Locally with an external pushbutton
Locally with built-in pushbutton
®
HART
command
Analog Input current threshold
Connecting the SVI II ESD to the SIS Logic Solver
When connecting the SVI II ESD to the SIS logic solver follow the guidelines below.
The SVI II ESD is connected to the safety rated logic solver which is actively performing
the safety function. Connections must be made as per the instructions supplied by the
safety rated logic solver.
The output rating of the I/O module has to meet or exceed the electrical specifications
of the SVI II ESD as referenced in ES-727 in the SVI II ESD Quick Start Guide,
MN-SVI-ESD_QSG-GEA19520.
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Masoneilan SVI II ESD Installation and Maintenance Manual =| 23
General Requirements
The following general requirements for the SVI II ESD must comply to the following:
The system response time shall be less than process safety time. The SVI II ESD
switches to its fail safe state in less than 100ms. Response time is actuator dependent.
The end user must add the SVI II ESD response time to actuator/valve response to
obtain overall response time.
All SIS components, including the SVI II ESD, must be operational before process
start-up. The internal diagnostic test monitoring SVI II ESD for faults has a one hour test
interval. This test does not partial stroke the valve.
In order to use the PST as an automatic diagnostic tool the PST shall be scheduled
(using ValVue ESD) to run at least once per month or ten times within the expected
hazard demand interval, whichever comes first. Detailed failure rate data is specified
in the FMEDA report available from the factory.
You must verify that the SVI II ESD is suitable for use in safety applications by
confirming that SVI II ESD’s nameplate is properly marked.
Personnel performing maintenance and testing on the SVI II ESD has to be qualified to
do so.
Results from the PST and proof tests shall be recorded and periodically reviewed.
The useful life of the SVI II ESD is discussed in the Failure Modes, Effects and Diagnostic
Analysis Report for the SVI II ESD.
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© 2016 General Electric Company. All rights reserved.
Installation
All installation related issues are outlined below.
SVI II ESD Installation Configurations
Refer to “SVI II ESD Configurations” on page 74
Physical Location and Placement Guidelines
Refer to “Physical Location and Placement Guidelines” on page 58
Pneumatic Connections
Refer to “Pneumatic Connections” on page 71 of this manual.
Electrical Connections
Refer to “Electrical Connection Guidelines” on page 73
Operation, Setup, Commissioning
Refer to “Configuration and Calibration” on page 87
Maintenance
Refer to “SVI II ESD Maintenance” on page 131.
Diagnostics
The SVI II ESD provides several types of diagnostic information:
Continuous device diagnostics
Internal diagnostics that run every hour and require no user configuration
Partial Stroke Testing (PST) diagnostics
PST
You can configure and run PST at any time. For more information on PST refer to “Partial
Stroke Testing” on page 115
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Masoneilan SVI II ESD Installation and Maintenance Manual =| 25
Proof Test
You can also manually run a proof test. The objective of proof testing is to detect failures
within an SVI II ESD and ESD valve that are not detected by any automatic diagnostic of the
system. Of main concern are undetected failures that prevent the safety instrumented
function from performing its intended function.
Proof testing frequency or proof test interval, has to be determined in reliability calculations
for the safety instrumented functions to which SVI II ESD is applied. The proof tests must be
performed more frequently or as frequently as specified in the calculation in order to maintain
the required safety integrity of the safety instrumented function.
The following proof test is recommended. Report any detected failures that compromise
functional safety to the factory.
Table 1 Proof Test Steps
Step
1
2
3 Inspect the SVI II ESD for dirty or clogged ports and other physical damage
4
5
6 Record any failures in your company’s SIF inspection database. Restore the loop to full operation.
7 Remove bypass or otherwise restore normal operation
Read the SVI II ESD data record using a HART
faults before proceeding.
Bypass the valve, or isolate or take other appropriate action to avoid a false trip, following company Management of Change (MOC) procedures
De-energize the SVI II ESD and observe that the actuator and valve move. Energize the SVI II ESD after the
valve has moved to its full stroke length.
Inspect the SVI II ESD for dirt, corrosion or excessive moisture. Clean if necessary and take corrective
action to properly clean the air supply. It has to be done in order to avoid incipient failures due to dirty air.
Action
®
handheld device or ValVue ESD software. Solve any active
This test detects approximately 99% of possible DU failures in the SVI II ESD (Proof Test
Coverage).
The person (s) performing the proof test of an SVI II ESD must be trained in SIS operations,
including bypass procedures, maintenance and company Management of Change
procedures. No special tools are required.
26 | =GE Oil & Gas
© 2016 General Electric Company. All rights reserved.
SVI II ESD Product Safety
The SVI II ESD is intended for use with industrial compressed air or sweet natural gas systems
only. Ensure that an adequate pressure relief provision is installed when the application of
system supply pressure may cause peripheral equipment malfunctioning. Installation must be
in accordance with local and national compressed air and instrumentation codes.
General installation, maintenance or replacement
Products must be installed in compliance with all local and national codes and
standards by qualified personnel using safe site work practices. Personal Protective
Equipment (PPE) must be used per safe site work practices.
Ensure proper use of fall protection when working at heights, per safe site work
practices. Use appropriate safety equipment and practices to prevent the dropping of
tools or equipment during installation.
Under normal operation, compressed supply gas is vented from the unit to the
surrounding area, and may require additional precautions or specialized installations.
Explosion/ flame proof installations
Products certified as explosion proof or flame proof equipment or for use in hazardous area
installations MUST BE:
Installed, put into service, used and maintained in compliance with national and local
regulations and in accordance with relevant standards recommendations for
potentially explosive atmospheres.
Used only in situations that comply with the certification conditions shown in this
document and after verification of their compatibility with the zone of intended use
and the permitted maximum ambient temperature
Installed, put into service and maintained by qualified and competent professionals
who have undergone suitable training for instrumentation used in areas with
potentially explosive atmospheres.
WARNING Before using these products with fluids/compressed gases other
than air or for non-industrial applications, consult the factory. This
product is not intended for use in life support systems.
WARNING Do not use damaged instruments.
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Masoneilan SVI II ESD Installation and Maintenance Manual =| 27
WARNING Installation in poorly ventilated confined areas, with any potential
of gases other than oxygen being present, can lead to a risk of
personnel asphyxiation.
Use only genuine replacement parts which are provided by the manufacturer, to guarantee
that the products comply with the essential safety requirements of the European Directives
mentioned on the front cover.
Changes to specifications, structure, and components used may not lead to the revision of
this manual unless such changes affect the function and performance of the product.
28 | =GE Oil & Gas
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2. Introduction
ValVue ESD Overview
Masoneilan's ValVue ESD software is a Human-Machine Interface (HMI) software tool that
provides a powerful interface to Masoneilan’s SVI II ESD used in a Safety Instrumented System
(SIS).
ValVue ESD is used to configure, calibrate and perform partial stroke testing and valve
diagnostics with the SVI II ESD utilizing HART
Using ValVue ESD you can:
Monitor SVI II ESD Operation Quickly Set Up the SVI II ESD
Advanced SVI II ESD Set Up Calibrate the SVI II ESD
Configure or Run Partial Stroke Test (PST) Check the SVI II ESD Status
Perform Diagnostics on SVI II ESD
®
communications protocol.
© 2016 General Electric Company. All rights reserved.
Figure 1 SVI II ESD
Masoneilan SVI II ESD Installation and Maintenance Manual =
| 29
The SVI II ESD LCD pushbutton display enables local operations for calibration and
configuration functions. Remote operations can be performed with ValVue ESD software or
any HART
®
Registered host interface pre-loaded with the Device Description file (DD) for SVI II
ESD.
The SVI II ESD is supplied with Masoneilan’s ValVue ESD software. The user-friendly interface
facilitates the setup and diagnostics of a SIS control valve.
ValVue ESD Software
ValVue ESD software is able to quickly and easily set up the SVI II ESD. In addition you can also
monitor operation and diagnose problems using ValVue ESD’s advanced diagnostic
capabilities.
ValVue ESD Trial Version
The SVI II ESD is supplied with ValVue ESD software. For a duration of 60 days after the initial
installation, ValVue ESD provides the capability of configuring, calibrating, diagnosing, device
cloning, trending and much more. After the 60 day trial period ValVue ESD must be registered
in order to keep on using it.
ValVue ESD is a user-friendly, graphical interface that allows an efficient setup of an SVI II ESD
mounted on any control valve assembly. Because of its What-You-See-Is-What-You-Get
(WYSIWYG) software environment, it is a very friendly user-interface.
ValVue ESD functionality includes:
Setup Wizard
Remote display of valve position, actuator pressure(s)
Set point calibration parameters
Set point configuration parameters
Set point status⁄error indicators
Input/Output configuration
Remote calibration of the SVI II ESD
Remote configuration of the SVI II ESD
Remote operation of the SVI II ESD
Remote Partial Stroke Test (PST) configuration
Remote running of Partial Stroke Test
Partial Stroke Test Scheduling
Saving and Viewing Historical data
Backup and restore configuration (clone device)
30 | =GE Oil & Gas
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