GE Masoneilan SVI II ESD Installation And Maintenance Manual

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GE Oil & Gas

GE Data Classification: Public

Masoneilan*

SVI* II ESD

Smart Valve Interface with SIL3 Emergency Shutdown PST Controller

Installation and Maintenance Manual

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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.

All information contained herein is believed to be accurate at the time of publication and is subject to change without notice.

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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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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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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.

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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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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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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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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

3 Inspect the SVI II ESD for dirty or clogged ports and other physical damage

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.

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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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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.

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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.

Figure 1 SVI II ESD

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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)

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 Trend setpoint, valve position, actuator pressure

 Display comparative test results

 Perform diagnostic test procedures

System Requirements

Listed below are the hardware and software requirements for the computer used with ValVue ESD:

Hardware

Processor PC with minimum 1 GHz Intel Pentium or compatible

RAM Minimum 1 G

Disk Depends on product

Modem HART

Port Serial or USB

modem and appropriate cables

Table 2 ValVue Software Installation Sizes

Product Application

Component

ValVue ESD 15M 30M minimum

PRM Central ValVue ESD 15M 30M minimum

PRM PLUG-IN ValVue ESD 15M N/A 15 Meg

Assuming 100 devices, 1 PST/month for 5 years

Database

Component

Total Installation Size

45 Meg

Software

Table 3 Software Requirements

OS: Windows XP SP2 Window Server 2003 with Service Pack 1, Window Server 2003 R2,

Windows Server 2008 and Windows 7

PRM: PRM R3.x

NOTE PRM is NOT required for Standalone installations.

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Installing ValVue ESD

ESDVue is shipped on a CD included with every SVI II ESD. Place the CD in the computer CD drive and run ValVue ESD Installer.exe. Follow the instructions of the installer program.

Advanced and Online Diagnostics

One of the important safety features of the SVI II ESD is the ability to test functionality of the instrument. In addition to running a Partial Stroke Test (PST), ValVue ESD provides advanced diagnostic capabilities and allows you to test the SVI II ESD terminal board and pneumatics and to run extended testing on the actuator. The diagnostics area of the PST screen provides access to all the diagnostic testing, shows the results from current testing and allows you to load and view historical data.

All diagnostic tests are performed on the PST screen, in ValVue ESD. For more details on the use of ValVue ESD software, refer to the ValVue ESD User’s Guide. Contact the factory or your local representative to obtain licensing information.

Contact the Factory

For the most recent software visit our SVI II ESD web site at: www.ge-energy.com/valves.

Available Models

There are three models of the SVI II ESD available:

 ASD - Analog Safety Demand; 2 Wire Analog Trigger, 4 - 20 mA signal, 2 wire

installations with superimposed HART

 DSD - Discrete Safety Demand; 2 Wire Discrete Trigger, 24 VDC, 2 wire installations with

superimposed HART

 A/DSD - Analog Setpoint with Discrete Safety Demand; 4 Wire Discrete Trigger, 4 - 20

mA signal, 2 wire installations with superimposed HART system and 24 VDC 2 wire for Safety System.

About This Manual

The SVI II ESD Instruction Manual is intended to help a Field Engineer install, setup, and calibrate an SVI II ESD in the most efficient manner possible. This manual also provides in-depth information on SVI II ESD software, digital interfaces, operation, intrinsic safety configurations, and specifications. If you experience problems that are not documented in this guide contact the factory or your local representative. Sales offices are listed on the back cover of this manual.

communications

communications for control

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3. Software Installation and Setup

Install ValVue ESD and PRM Plug-In

ValVue ESD is shipped on a CD with the purchase of an SVI II ESD. There are two components to install:

 “Installing ValVue ESD Software”

 “Installing the Yokogawa® PRM Plug-In” on page 37

Installing ValVue ESD Software

To install the software:

1. Insert the CD into computer CD drive.

The CD browser launches (Figure 2).

Figure 2 ValVue ESD CD Browser

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2. Select INSTALL SOFTWARE and a screen appears (Figure 3).

Figure 3 Software Choice

3. Click INSTALL STANDALONE VERSION and an installShield screen appears (Figure 4).

Figure 4 Install Shield Wizard

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4. Click Next and the License Agreement screen appears (Figure 5).

Figure 5 License Agreement

5. Click the accept radio button, click Next and the Choose Destination Location screen appears (Figure 6).

Figure 6 Choose Destination Location

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NOTE Click Change to open the Choose Folder screen to navigate to and

designate a non-default folder.

6. Click Next and a screen appears (Figure 7).

Figure 7 Ready to Install

7. Click Install and the Setup Status screen appears followed by InstallShield Wizard Complete.

8. Click Finish.

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Installing the Yokogawa® PRM Plug-In

This process consists of:

 “Installing Central Server”

 “Installing Plug-In Client” on page 43

Installing Central Server

This installs both the plug-in and the central database.

To install the software:

1. Insert the CD into computer CD drive and the CD browser launches (Figure 2).

Figure 8 ValVue ESD CD Browser

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2. Select INSTALL SOFTWARE and a screen appears (Figure 9).

Figure 9 Software Choice

3. Click VIEW YOKOGAWA PRM EDITION and a screen appears (Figure 10).

Figure 10 PRM Plug-In Main Screen

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4. Click Install Central Server and a screen appears.

5. Click Next and the License Agreement screen appears (Figure 11).

Figure 11 PRM Central Server License Agreement

6. Click the accept radio button, click Next and the Choose Destination Location screen appears (Figure 12).

Figure 12 PRM Central Server Destination Folder

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NOTE Click Change to open the Choose Folder screen to navigate to and

designate a non-default folder.

7. Click Next and the screen appears (Figure 13).

CAUTION Click Change to open the Choose Folder screen to navigate to and

designate a non-default folder. Make a note of this machine and folder share name, ValVue ESD DATABASE as it is required when installing the PRM PLUG-IN ValVue.The installer also creates a data source for the database. If the database already exists, the installer updates the tables as necessary. No existing data is lost .

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Figure 13 PRM Central Server Database Directory Destination Folder

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8. Click Next and a screen appears (Figure 14).

Figure 14 Ready to Install

9. Click Install and the Setup Status screen appears followed by InstallShield Wizard Complete.

10. Click Finish.

11. A Launch Service Install dialog appears; click OK and a dialog appears (Figure 15).

Figure 15 PRM Central Server Dialog

12. Click OK and another dialog appears (Figure 16).

Figure 16 PRM Central Server Dialog II

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13. Click OK and another dialog appears (Figure 17).

Figure 17 PRM Central Server Dialog III

14. Click OK and another dialog appears (Figure 18).

Figure 18 Database Directory Reminder

15. Click OK.

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Installing Plug-In Client

This installs the plug-in and the client software and a database. Install this application on every computer on which PRM Client is installed after PRM Central is installed for the particular PRM server. This application does not require registration.

To install the software:

1. Insert the CD into computer CD drive and the CD browser launches (Figure 19).

Figure 19 ValVue ESD CD Browser

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2. Select INSTALL SOFTWARE and a screen appears (Figure 20).

Figure 20 Software Choice

3. Click VIEW YOKOGAWA PRM EDITION and a screen appears (Figure 21).

Figure 21 PRM Plug-In Main Screen

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4. Click Install Plug-in Client and a screen appears (Figure 22).

Figure 22 Install Shield PRM Plug-In

5. Click Next and the License Agreement screen appears (Figure 23).

Figure 23 PRM Plug-In License Agreement

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6. Click the accept radio button, click Next and the Choose Destination Location screen appears (Figure 24).

Figure 24 PRM Plug-In Destination Folder

7. Click Change and the Choose Folder dialog appears (Figure 25).

Figure 25 Choose Folder

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8. Navigate to the desired folder, click OK and Next and the screen appears (Figure 26).

CAUTION Use the same folder as with the ValVue ESD DATABASE.The

installer also creates a data source for the database. If the database already exists, the installer updates the tables as necessary. No existing data is lost.

Figure 26 PRM Plug-In Client Database Location Destination Folder

9. Click Change and the Choose Folder dialog appears (Figure 27).

Figure 27 Choose Folder

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10. Navigate to the desired folder, click OK and Next and the screen appears (Figure 28).

Figure 28 Ready to Install

11. Click Install and the Setup Status screen appears followed by InstallShield Wizard Complete.

12. Click Finish.

PRM PLUG-IN ValVue ESD Warning

Listed below are warnings pertaining to the installation of the PRM PLUG-IN ValVue ESD.

PRM Multi-Server

Because of the connection with the database and Central ValVue ESD, the Multi-Server switching feature, available on the PRM client, is not allowed.

PRM PLUG-IN ValVue ESD Installation Folder

As mentioned in installation instructions, the PlugInValVue ESD application must be installed to the same drive and folder on every machine

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Registering ValVue ESD

When you start ValVue ESD for the first time the registration window launches. ValVue ESD software must be registered to activate the permanent installation. ValVue ESD can be used without registration for 60 days. Registration allows the factory to keep track of all of ValVue ESD users so that we can notify you of any changes or important information about new software features and updates. A registration card is included with the installation CD.

The software package contains a serial number. Keep a record of the serial number in a secure location. Do not discard the registration card. To register your software, you must launch the ValVue to obtain an installation ID number, then contact the factory by mail, telephone, email or Fax, and provide your name, company’s name, contact information, the CD-ROM serial number, and the installation ID number from the ValVue ESD login display.

Factory contact information is provided on the registration card that is part of the software

package.

Your serial number is located on the ValVue ESD package and on the enclosed sticker. Place the serial number sticker on the detachable card included with the Registration Instruction card and store the card in a secure location. You need the serial number to move ValVue ESD to a different computer.

Masoneilan Software Registration Center provides you with software keys that you enter the next time you run the program. Contact the factory for a new software key if you are moving ValVue ESD to a different computer or, if you do not have a serial number.

To register ValVue ESD:

1. Start ValVue ESD either by clicking on the desktop icon or using the Start programs selection. When you start ValVue ESD, the registration window appears (Figure 29).

Figure 29 Owner and Product Key Registration Window

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2. Enter Name, Company and Serial Number in the registration and click OK.

Figure 30 Applying Owner and Product Key Information

The software key registration window appears (Figure 31).

3. Click Mux and enter a software key for the Mux option, if applicable.

Figure 31 Software and Mux Key Window

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4. Click Registration (Figure 32).

Figure 32 Launching Registration Window

5. Enter your name and the name of your company. You are now ready to contact the factory with this information, to obtain your software keys. There are four methods shown on the Registration Instruction Card:

 Mail

 Phone

 Fax

 Email

Figure 33 Registration Window

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6. Click Save to File to save your registration file. A Windows browser appears (Figure 34).

7. Navigate to the desired folder, name the registration information (.txt) file and click Save.

Figure 34 Save Registration Information

A dialog appears (Figure 35).

8. Email the registration information by clicking Yes.

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Figure 35 Registration File Saved Dialog

ValVue ESD launches your email service and automatically attaches the registration and Masoneilan’s Software Registration Center.

9. Click Send to email the registration.

If your email program fails to start, contact the software registration center using the email address, phone number, address, or fax number given on the registration card (contained with the ValVue ESD cd).

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A dialog indicating the email has been sent appears (Figure 36).

10. Click OK to close the dialog.

Entering Software Keys

After you have sent the registration info, you are provided with software keys for ValVue ESD and optional features (when applicable).

Once you have your key, to enable the program:

1. Start ValVue ESD.

2. Choose Help > View Registration.

Figure 36 Registration Email Sent Dialog

3. Enter the Product Key (if not already entered).

4. Click OK. On the 2nd registration screen, enter the software key returned by the factory (Figure 37).

Figure 37 Entering Software Key

5. Enter the software key, if applicable, by clicking on the screen under the Unlock Keys field and the field becomes active. Enter the Mux software key.

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6. Click OK.

Figure 38 Entering Mux Unlock Key

When the registration is complete and successful the message shown in Figure 39 appears.

7. Click OK.

Figure 39 Successful Registration Message

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4. Installation and Setup

NOTE

SVI II ESD Cover

SVI II ESD Assembly

Electronics

Module

Pneumatic Train and

Cover (I/P Module, Relay)

Manifold

Relay

I/P

Overview

Figure 40 shows the SVI II ESD positioner which is designed to prevent and mitigate possibly negative situations. It is a position controller assembled on a pneumatically actuated valve assembly. Its role is to position an emergency shutdown valve to 0% or 100% with a probability of failure on demand (PFD) in accordance with IEC61508 for SIL3 application. It replaces solenoid valves typically utilized to actuate a spring-return. This section provides detailed procedures for installing the SVI II ESD.

Prior to beginning the installation process review the “Safety Information” on page 17.

Figure 40 SVI II ESD Exploded View

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SVI II ESD Dimensions and Weights

122.55 mm

34.00 mm

1.90 mm

38.10 mm

47.58 mm

74.97 mm

96.56 mm

34.00 mm23.00 mm

(74.97 mm)

203.93 mm

8.03 in

4.825 in

4.93 in

125.33 mm

1.34 in

0.075 in

(1.90 mm)

(0.075 in)

4.19 in

106.36 mm

2.1 in

53.18 mm

1.5 in

1.87 in

2.95 in

3.8 in

145.37 mm

5.72 in

1.34 in

.90 in

(2.95 in)

Standard Weight - 7.4 lbs (3.357 kg)

Center of Gravity

Stainless Steel Housing Weight - 16 lbs/ 7.257 kg

Figure 41 illustrates the dimensions and weight of the SVI II ESD.

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Figure 41 SVI II ESD Dimensions

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Pre-Installation Issues

Storage

If the SVI II ESD is stored for a long period of time, you must keep the housing sealed against weather, fluids, particles, and insects. To prevent damage to the SVI II ESD:

 Use the plugs provided with shipment to plug the ¼ NPT air connections, on the

positioner and on the air filter regulator set.

 Do not allow standing water to accumulate in packaging.

 Observe storage temperature requirements.

Unpacking

Exercise care when unpacking the control valve and its mounted accessories. The SVI II ESD package contains a CD-ROM with ValVue ESD software and manuals.

WARNING Failure to adhere to the requirements listed in this manual can

cause loss of life and property. Before installing, using, or carrying out any maintenance tasks associated with this instrument, READ THE INSTRUCTIONS CAREFULLY.

Installation

The steps necessary to complete the SVI II ESD installation and software setup are outlined in Table 4.

Table 4 SVI II ESD Installation Steps

Step No. Procedure Reference

1 Attach mounting bracket to the actuator. See page page 461 for rotary valve and page 466

for reciprocating valve instructions.

2 Install the SVI II ESD magnetic assembly (rotary

valves only).

3 Assemble the SVI II ESD on the bracket that is

mounted to the valve actuator.

4 Connect the pneumatic tubing to the SVI II ESD. See page 471 for instructions.

5 Connect the air supply to the SVI II ESD. See page 473 for instructions.

6 Install the wiring for the SVI II ESD. See page 473 for instructions.

7 Connect the PST controller to the HART® Control

Loop segment by installing the SVI II ESD wiring.

See page 461 for instructions.

See page 461 for rotary valve and page 466 for reciprocating valve instructions.

See page 476 for instructions.

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Table 4 SVI II ESD Installation Steps (Continued)

Step No. Procedure Reference

8 Power up the SVI II ESD. See page 478 for instructions.

9 Configure/calibrate using ValVue ESD See “Configuration” on page 88.

WARNING Failure to adhere to this manual’s requirements can cause loss of

life and property. Before installing, using, or doing maintenance tasks associated with this instrument, READ THE INSTRUCTIONS CAREFULLY.

Physical Location and Placement Guidelines

When determining the location of the SVI II ESD adhere to the following guidelines:

 Allow sufficient room for cabling and pneumatic connections and for manual proof

testing.

 Keep pneumatic piping to the actuator as short and straight as possible to minimize

the airflow restrictions and potential clogging of the line. Long or kinked pneumatic tubes can also increase the valve closure time.

 Keep the Breather/Vent port accessible and for inspection for obstruction during

manual proof testing.

 Mount the SVI II ESD in a mild vibration environment. If excessive vibration can be

expected, take special precautions to ensure the integrity of electrical and pneumatic connectors or reduce the vibration using appropriate damping mounts.

Necessary Precautions

To avoid injury or affecting the process when installing or replacing a PST controller on a control valve, ensure that:

1. If the valve is located in a hazardous area make sure the area has been certified as safe or that all electrical power to the area has been disconnected before removing any covers or disconnecting any leads.

2. Shut off air supply to the actuator and to any valve mounted equipment.

3. Ensure the valve is isolated from the process by either shutting off the process or using bypass valves for isolation. Tag shutoff or bypass valves to guard against a turn-on while work is in progress.

4. Bleed air from actuator and check that valve is in its de-energized position.

It is now safe to disconnect and remove any valve mounted equipment that is being replaced.

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Page 59

Natural Gas Supply Considerations

If the pneumatic system is connected to natural gas, the pneumatic control system constantly bleeds a small amount of the natural gas into the area around the SVI II ESD. Also, during a vent cycle (actuator pressure relief), natural gas from the actuator is released into the area around the SVI vent port. Consider both sources of natural gas when evaluating the Hazardous Classification for the area.

Remote piping of the actuator venting is possible to reduce the amount of natural gas released into the area around the SVI II ESD. Installing remote actuator vent gas piping does not capture all gas emitted. A small amount of natural gas still bleeds constantly in the area around the SVI II ESD. Consider the bleeding and releasing of natural gas when evaluating the Hazardous Clarification for the area.

Refer to “Installing an SVI II ESD in a Natural Gas Environment” on page 165 for installation instructions.

NOTE Area classification is the responsibility of the end user.

WARNING Do not remove the instrument cover or connect to an electrical

circuit unless the power is disconnected. Natural gas will escape into the surrounding atmosphere upon disconnecting any of the pneumatic connections or removing any cover or pressure containing component.

WARNING EXPLOSION HAZARD - DO NOT DISCONNECT EQUIPMENT OR

REMOVE COVER UNLESS POWER HAS BEEN DE-ENERGIZED OR THE AREA IS KNOW TO BE NON-HAZARDOUS.Natural Gas may be contained within the SVI II ESD. Even after disconnecting the SVI II ESD from all the pneumatic connections Natural Gas may still be present within the SVI II ESD.

WARNING EXPLOSION HAZARD - NATURAL GAS MAY EXCAPE FROM THE SVI

II ESD UPON REMOVAL OF ANY COVER OR COMPONENT. Ensure the cover is correctly installed before putting this unit into service.

WARNING EXPLOSION HAZARD - AN IMPROPERY INSTALLED COVER COULD

LEAK NATURAL GAS INTO THE AREA. The interior of the SVI II ESD is positively pressure with supply medium. Appropriate safety measures must be taken to handle pressurized natural gas that may enter the electrical conduit or cable system.

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WARNING EXPLOSION HAZARD - A MISSING OR IMPROPERY INSTALLED

CONDUIT SEAL, CABLE SEAL, OR CABLE GLAND COULD LEAK NATURAL GAS INTO THE CONDUIT/CABLE SYSTEM, AND/OR INTO ANY AREA WHERE THE COUDUIT/CABLING SYSTEM IS PRESENT OR CONNECTED TO.

WARNING Natural gas will constantly bleed and possibly vent from the SVI II

ESD if connected to a natural gas supply. Hazardous area clarification is the responsibility of the end user. area ventilation and other safety measures may be required to maintain a safe environment.

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.

WARNING Isolate the valve from the process and disconnect air tubing from

the positioner. Disconnect air fully to avoid injury or process damage.

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Page 61

Mounting the SVI II ESD on Rotary Valves

This section describes the procedure for mounting the SVI II ESD on rotary control valves that have less than 60° rotation, such as a Camflex a Camflex actuator and the SVI II ESD actuator mounting brackets.

Figure 42 Camflex with Mounting Bracket (Side View)

Mounting the SVI II ESD on a Rotary Actuator

Tools required:

 3⁄16" Hex Key

 5⁄32" Hex Key

 3 mm, 4 mm, 5 mm Hex Key

or a Varimax*. Figure 42 shows a side view of

 7⁄16" Wrench

To mount the SVI II ESD:

1. Attach the SVI II ESD rotary mounting bracket to the valve actuator using two (2) 5⁄16 - 18 UNC flat-head cap screws. In the preferred mounting position, the long end of the mounting bracket is on your left when facing the actuator, for any position of the valve and actuator.

2. Bolt the extension shaft to the valve position take-off shaft using a 1⁄4 - 28 UNF socket flathead screw. Secure the machine screw holding the extension shaft with a torque of 144 in-lbs (16.269 N-m).

3. On internal valve pressure the thrust shaft is pushed out to the mechanical stops, usually a thrust bearing. On valves where the valve position take-off is mounted directly on the end of the plug shaft, a Camflex for example, the shaft must be bearing on its stop to properly set up the SVI II ESD PST controller. During hydrostatic testing the shaft is thrust to its stop and a normally tightened packing retains it in that position.

4. On vacuum service, the valve shaft may be drawn into the body by the vacuum acting on the shaft, but the magnetic coupling must be assembled flush with the mounting bracket with the shaft pulled fully out to its thrust bearing. Check that the endplay from the vacuum position to the fully extended position is less than 0.06 in. (1.524 mm)

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Page 62

5. Slide the magnet holder into the extension shaft. The location of the magnets is in the ring of the magnet holder. The magnetic axis is the imaginary line through the center of both magnets.

6. Rotate the magnet holder so that the magnet axis is vertical when the valve is in the closed position.

7. Align the end of the magnet holder flush with the end of the mounting bracket. Secure the magnet holder with two M6 set screws.

8. Slide the V-Seal over the magnet holder.

9. Secure the SVI II ESD onto the mounting bracket using four M6 x 20 mm Socket Head Cap Screws.

10. Ensure no interference exists with the position sensor protrusion.

11. Ensure that the V-Seal makes contact with the skirt around the position sensor protrusion on SVI II ESD housing.

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Page 63

Travel Sensor Alignment

Table 5 shows the general guidelines for travel sensor alignment . Review the table prior to installing the SVI II ESD on a rotary valve actuator for proper alignment of the magnet .

Table 5 Travel Sensor Alignment

Rotary

Mounting

System

Rotary <60° Rotation

Stroke Direction Magnet

Clockwise or counterclockwise rotation

>60° Rotation

Clockwise with increasing setpoint

>60° Rotation

Counter Clockwise rotation with increasing setpoint

Orientation

(0°)

(-45°)

Valve Position Sensor Counts

Closed (0%) 0 +/- 1000

Full Open

Full Closed

Full Open

Full Closed

-8000 +/- 1500

+8000 +/- 1500

-8000 +/- 1500

+8000 +/- 1500

General Rule for other configurations

Any amount of rotation Clockwise or counterclockwise

Dismantling the SVI II ESD from Rotary Valves

WARNING Before carrying out any work on the device, power off the

instrument or ensure that the device’s location conditions for potentially explosive atmosphere permit the safe opening of the cover.

To remove the SVI II ESD PST controller from a rotary valve perform Steps 1 - 9 on page 461 in reverse.

(+45°)

(0°)

50% Travel

(Mid-Stroke)

0 +/- 1000

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Mounting the SVI II ESD with NAMUR Kits

Mounting Bracket

Indicator Disc Bracket

Quarter Turn Mounting Plate

There are two versions of this kit:

 20 and 30 mm

 50 mm

20 and 30 mm Mounting

Tools required:

 3 mm hex key

 4 mm hex key

Refer to Figure 43 for this procedure.

To mount using this kit:

1. Attach the mounting bracket to the valve actuator using four (4) M5 x 0.8 x 10 flat-head cap screws.

64 | =GE Oil & Gas

Figure 43 Namur 20/30 mm Mounting Kit

2. Place the indicator disk with metal insert over the valve actuator shaft and secure using an M6 x 1.0 x 45 socket-head screw.

3. Place the Quarter Turn Mounting Plate into place sliding it through the anti-backlash spring into the dowel pin at the end of the plate into the hex head screw installed in step 2.

4. Secure the plate to the bracket using four (4) flat head cap screws.

Page 65

50 mm Mounting

Mounting Bracket

Namur coupling w/lever

Anti-backlash spring

Quarter Turn Mounting Plate

Tools required:

 3 mm hex key

 4 mm hex key

Refer to Figure 44 for this procedure.

To mount using this kit:

1. Attach the mounting bracket to the valve actuator using four (4) M5 x 0.8 x 10 flat-head cap screws.

2. Place the indicator disk with metal insert over the valve actuator shaft .

Figure 44 Namur 50 mm Mounting Kit

3. Place the Namur coupling and lever on top of the indicator disc and secure with an M6 x

1.0 x 25 socket-head screw.

4. Place the Quarter Turn Mounting Plate into place sliding it over the lever and through the anti-backlash spring.

5. Secure the bracket using four (4) flat head cap screws.

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Mounting the SVI II ESD on Reciprocating Valves

M5 Flat head screw

The process of mounting the SVI II ESD on a reciprocating valve consists of mounting the unit on the actuator that is attached to the valve. This section describes the procedure for mounting the SVI II ESD on Reciprocating Valves (using Masoneilan’s 87⁄88 Multi-Spring actuators as an example).

Mounting the SVI II ESD on a Reciprocating Actuator

Tools required:

 7⁄16" Combination Wrench (2 required)

 3⁄8" Combination Wrench

 1⁄2" Combination Wrench

 Phillips Head Screw Driver

 5 mm Hex Key Wrench

1. Ensure that the lever is pinned to the magnet assembly and held securely by an M5 flat head screw to ensure that the magnet axis is vertical when the lever is in the valve closed position. Tighten the lever screw securely. Refer to Figure 45.

66 | =GE Oil & Gas

Figure 45 Magnet Holder for Reciprocating Valves

2. Mount the SVI II ESD reciprocating mounting bracket to the actuator using two (2) 5⁄16 - 18 UNC cap screws.The mounting location of the bracket depends on the size and stroke of the actuator. Refer to Figure 46 and Figure 6 on page 68.

Figure 46 Reciprocating Valve Mounting Bracket

Page 67

3. Select mounting hole A, B, C or D for the stroke of the valve. For example, hole B is shown in Figure 46 on page 66 for a size 10 actuator with 1.0" stroke. Unless otherwise specified, the SVI II ESD mounting assumes that the actuator is in the normal upright position. The mounting hole in the slotted opening of the mounting bracket must be left when facing the actuator, with the actuator in the upright position.

4. Thread the take-off rod to the actuator stem connector. Refer to Figure 47. Ensure that the travel pointer located on the coupling is correctly positioned.

5. Attach the right hand threaded rod end to the SVI II ESD lever using a 1⁄4 - 20 x 1" cap screw and nut as shown. The lever hole position to be used depends upon the specific valve stroke. Refer to Figure 47 on page 67 and the Reciprocating Valve Linkage Selection, Table 6 on page 68.

6. Thread the right hand lock nut and turnbuckle onto the right hand rod end approximately two turns. Turnbuckle length is a function of actuator size. (Refer to Table 6 on page 68.)

7. Secure the magnet housing assembly, including the lever and right hand rod end, to the bracket using four M5 X 10 mm flat head screws.

8. Attach the left hand threaded rod end to the take-off rod with 1⁄4 - 20 UNC nut and thread the left hand lock nut onto the rod end.

Figure 47 Reciprocating Linkage

9. Move the valve to its closed position. For air to extend, this requires using air pressure in the actuator to fully stroke the actuator. For air to retract, actuators vent the actuator of air pressure.

10. Thread the turnbuckle onto the left hand threaded rod end. Refer to Figure 47.

11. Adjust the turnbuckle until the hole in the SVI II ESD lever is aligned with the indicating hole in the bracket. Tighten both turnbuckle lock nuts. Refer to Figure 47.

12. For reciprocating valves the adjustable link turnbuckle must be parallel to the valve stem. To ensure linearity in positioning, verify that the hole in the lever aligns with the indicating hole in the bracket when the valve is in the closed position. Check that the bracket is mounted using the proper holes. (Refer Table 6 on page 68.).

13. Mount the SVI II ESD to the bracket and secure with four M6 socket head cap screws.

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Figure 48 Lever for Model 87/88 Multispring Actuator

Table 6 Reciprocating Valve Mounting Hole and Turnbuckle Length

Actuator Size

Stroke Mounting

Masoneilan

6 and 10 0.5 - 0.8"

(12.7 - 20.32 mm)

10 0.5 - 0.8"

(12.7 - 20.32 mm)

10 >0.8 – 1.5"

(20.32 - 41.5 mm)

16 0.5 - 0.8"

(12.7 - 20.32 mm)

16 >0.8 – 1.5"

(20.32 - 41.5 mm)

16 >1.5 – 2.5"

(41.5 - 63.5 mm)

23 0.5 - 0.8"

(12.7 - 20.32 mm)

23 >0.8 – 1.5"

(20.32 - 41.5 mm)

Hole

Lever

Hole

Turnbuckle

A A 1.25"

(31.75 mm)

A A 1.25"

(31.75 mm)

B B 1.25"

(31.75 mm)

B A 2.90"

(73.66 mm)

C B 2.90"

(73.66 mm)

D C 2.90"

(73.66 mm)

B A 5.25"

(133.35 mm)

C B 5.25"

(133.35 mm)

Length

68 | =GE Oil & Gas

23 >1.5 – 2.5"

(41.5 - 63.5 mm)

D C 5.25"

(133.35 mm)

Page 69

Dismantling the SVI II ESD from Reciprocating Valves

WARNING Before carrying out any work on the device, power off the

instrument or ensure that the local conditions for potentially explosive atmosphere permit the safe opening of the cover.

To remove the SVI II ESD PST controller from a reciprocating valve perform Steps 1 - 12 in the reverse order.

Checking the Magnet

There are two methods of checking the SVI II ESD magnet:

 Perform a visual inspection

 Use ValVue ESD to check the magnet

Performing a Visual Inspection

To perform a visual inspection refer to Table 5 on page 63 and ensure that the magnet is correctly oriented for the actuator/valve configuration.

Using ValVue ESD to Check Magnet Position

Use this procedure to check the magnet using ValVue ESD (provided with SVI II ESD). Also refer to Table 5 on page 63 for sensor information.

1. Connect to the PST controller in accordance with the ValVue ESD instructions. For further information refer to the ValVue ESD On Line Help or Instruction Manual.

2. After the PST controller has been installed and set up with a HART compliant communications loop, install ValVue ESD on the computer that is connected to the HART

3. Run ValVue ESD.

4. Select the installed ESD PST controller from the list of Connected Devices as shown in Figure 49 and click Connect.

5. Select the: Check tab to view the current operating conditions of the selected PST controller.

6. Read Raw Position Data on the Check screen as shown in Figure 49.

7. The Raw Position Sensor value measured must in accordance with the Table 5 on page 63.

modem.

Modem in a HART®

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Figure 49 ValVue ESD for Checking Magnet Position

ValVue ESD Connected Devices Screen

ValVue ESD Check Screen

Checking Actuator, Linkages, or Rotary Adapter

Verify that the mounting has not been damaged in shipment for a pre-mounted SVI II ESD, physically inspect the actuator, linkage. Record the following information for the configuration checkout:

 Valve Air to Open (ATO) or Air to Close (ATC)

 Actuator pressure rating

 Actuator bench range

 Inherent trim characteristic of the control valve; linear, equal percentage, or other.

NOTE For the aforementioned information, refer to the valve data sheet

or model number of control valve.

Verify Mounting and Linkage Adjustment

Inspect the mounting and make any needed adjustments before running the PST controller and checking the digital configuration.

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Page 71

Connecting the Tubing and Air Supply

NOTE It is advisable to tube and apply the air supply to the SVI II ESD

before connecting the electrical input signal to power it up.

NOTE For small actuators it may be necessary to use 1/8" tubing for

Autotune to work properly.

This section describes the process for connecting the tubing and air supply to a single acting PST controller.

Pneumatic Connections

The SVI II ESD is intended for use with industrial compressed air or natural gas systems only that meet the requirements of ISA standard 7.3. Supply pressure must not exceed 120 psi. A coalescing filter can be used to assure that the supply air is sufficiently free of oil, water, and particulate contaminants. Ensure that an adequate pressure relief provision is installed when the application of system supply pressure could cause peripheral equipment to malfunction. Installation must be in accordance with local and national compressed air and instrumentation codes. Table 7 provides the pneumatic connections and air supply requirements for the SVI II ESD.

Table 7 Pneumatic Connections/Air Supply Requirements

Recommended Piping Inlet/Outlet

Instrument Air Pressure 30 - 120 psi (2.07 - 8.27 bar) (207 - 827 kPa)

Dew Point At least 18° F (-8° C) below minimum anticipated ambient tem-

Particulate Matter Filtered to 5 microns

Oil Content Less than 1 ppm w/w

Contaminants Free of all corrosive contaminants

1/2” stainless steel or PVC tubing. The length of tubing between the SVI II ESD and the valve shall be kept as short as possible and free of kinks

perature

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Page 72

Single Acting PST Controller

Output

Supply

WARNING Isolate the valve from the process and disconnect air tubing from

The supply and output connections for the SVI II ESD, located on bottom of the pneumatic block, are 1⁄4" NPT threaded. Output is toward the front, supply is toward the back.

Maximum allowable air supply pressure to the SVI II ESD varies according to actuator, valve size, and valve type. Refer to the serial plate of the valve to know the specified supply pressure; it must never be less than the maximum spring pressure +10 psi.

the PST controller. Disconnect air fully to avoid injury or process damage.

1. Install the tubing to the air supply port (S



2. For a single acting actuator - pipe the outbound air from the output pressure port ( the actuator.

3. Air supply:

 Supply pressure for single acting SVI II ESD:

30 -120 psi (2.07 - 8.28 bar) (207- 827.6 kPa)

 Minimum tubing diameter 1⁄4" (6mmx4mm)



I) to

72 | =GE Oil & Gas

Figure 50 Air Ports on Single Acting PST Controller

Page 73

Checking the Air Supply

Use this procedure to check the air supply.

1. Turn on the air supply.

2. Adjust the filter regulator.

3. Supply pressure must be a minimum of 10 psi greater than the spring range of the actuator but can not exceed the rated actuator pressure. Refer to the valve or actuator instruction manual.

4. Inspect the tubing connections between the filter-regulator and the PST controller for leaks.

5. Verify that the tubing is not bent or crushed.

6. Verify that all fittings are leak tight.

NOTE Do not use Teflon pipe seal tape. The Teflon tape can shred into

For detailed information on pneumatic connections refer to “Pneumatic Connections” on page 71.

particles that are harmful to the pneumatic components.

Wiring the SVI II ESD

There are two components to wiring the SVI II ESD; making an electrical connection for power and making a local control loop connection for HART

Electrical Connection Guidelines

When making the SVI II ESD electrical connections, follow these guidelines:

1. The SVI II ESD device is available in two control signal configurations: 4-20 mA or 0/24 VDC.

2. Provide sufficient electrical isolation between adjacent signal lines and between signal lines and ground for all wiring.

3. Use stranded 14 to 22 AWG (or equivalent gauge and flexibility).

4. Use conduit sealant to prevent condensation from entering the enclosure and, in Class 1 Div. 2 conditions to prevent hazardous gases and vapors from migrating through the conduit to the control room or an open ignition source.

5. Wire according to the National Electrical Code (ANSI-NFPA 70) or other applicable local codes.

6. The terminal clamps are designed for one wire only; DO NOT attempt to terminate multiple wires into one terminal.

communication.

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Page 74

7. Strip the wires to the recommended length (See product specifications).

8. Ensure all wire stands are fully inserted into the terminal block and no shorts between adjacent wires on the terminal block are possible.

9. Use care when running signal wiring near to or crossing conduit or wiring that supplies power to motors, solenoids, lighting, horns, bells, etc. Provide sufficient electrical isolation and shielding against electro-magnetic interference from items in the vicinity of the cable run.

10. Run AC power wiring in a separate conduit from DC power. All power wiring to and from the SVI II ESD should be in grounded conduit. Protect outdoor cable runs against lightning strike.

11. Connect the SVI II ESD to a high quality instrument grade ground sized as required by local electrical codes. A grounding stud is provided inside the enclosure.

WARNING Comply with current national and local regulations for electrical

installation work. Comply with national and local explosive atmosphere regulations.

Before carrying out any work on the device, power off the instrument or make sure that the locale conditions for potentially explosive atmosphere permit the safe opening of the cover.

CAUTION Refer to“Output Switches” on page 127 for guidelines on safely

SVI II ESD Configurations

There are three possible SVI II ESD installation configurations each with a different wiring scheme.

 Analog Safety Demand (ASD)

 Discrete Safety Demand (DSD)

 Analog with Discrete Safety Demand (A/DSD)

wiring switch load limits.

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Page 75

Analog Safety Demand (ASD)

SVI II ESD

4 - 20 mA + HART

2 Wire Solution - Safety Function Triggered by Current Sensing (5.6mA = Safety Trip)

Control System

Safety System

SVI II ESD

24 VDC + HART

Safety Function Triggered by Discrete 0 - 24 VDC Signal (3 VDC = Safety Trip)

Control System

Safety System

High Impedance Device Required for HART Signaling

The Analog Safety Demand configuration is: 4 - 20 mA signal, power and trip signal with superimposed HART

Figure 51 Analog Safety Demand (ASD) Configuration

Discrete Safety Demand (DSD)

The Discrete Safety Demand configuration is: 24 VDC, power and trip signal with superimposed HART

communications (Figure 51).

communications (Figure 53).

Figure 52 Discrete Safety Demand (DSD) Configuration

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Page 76

Analog with Discrete Safety Demand (A/DSD)

SVI II ESD

Setpoint 4- 20 mA+ HART

4 Wire Solution -Safety Function Triggered by Discrete 0 - 24 VDC Signal (3VDC = Safety Trip)

Control System

Safety System

Safety Trip Signal Discrete 3 VDC- 24 VDC

or Safety System

The Analog with Discrete Demand configuration is: 4 - 20 mA power input with superimposed

HART

communications for control system and 24 VDC 2 wire for Safety System (Figure 53).

Figure 53 Analog with Discrete Safety Demand (A/DSD) Configuration

HART

Wiring Guidelines

In order for the SVI II ESD to communicate, the SVI II ESD must be physically connected to a

HART

compliant network. “Connecting to the Control Loop” outlines wiring the SVI II ESD.

Connecting to the Control Loop

The SVI II ESD PST controller MUST BE grounded according to local regulations. It is important to maintain correct polarity at all times, otherwise the PST controller may not operate properly. Physically connect the SVI II ESD to the HART

HART

Communication Foundation. A shielded cable is recommended.

To connect the Control Loop to the SVI II ESD:

1. Connect one end of the cable to the control loop's 4 - 20 mA output.

2. Remove the threaded wiring covers on the PST controller.

3. Connect the other end of the cable to the SVI II ESD. There are two threaded openings on the PST controller. Use the opening with the red plastic insert .

4. Maintain polarity + and - respectively.

NOTE Position Retransmit: when wiring this feature:

loop using a cable specified by the

Wire using the same gauge wire as for the 4-20 mA control loop.

In general, ensure that it is connected to the control system’s analog systems card.

76 | =GE Oil & Gas

Ensure the control loop is powered when using a meter to make any measurements.

Page 77

Wiring a Position Retransmit

CAUTION For proper operation, maintain signal polarity + and - respectively.

To connect:

1. Strip approximately 1/4” (6.35 mm) of the insulation at the end of wires (wire size 14 to 28 AWG, 2.5 mm2 to .08 mm2).

2. Connect the +⁄- terminals from the 4-20 mA Out to the position retransmit input signal: + to + and - to -. See Figure 54 on page 81, Figure 55 on page 82 or Figure 56 on page 82, depending on card type.

To troubleshoot retransmit connections:

 Ensure that the retransmit circuit has a minimum voltage of 10 V (maximum 30 V).

 Ensure the minimum AO current is 3.2 mA. If the module loses power and the AO circuit

remains powered, the AO signal will be 3.2 mA.

Compliance Voltage in Single Drop Current Mode

The SVI II ESD requires 9.6 V at 20 mA and 11.0 V at 4 mA. Typical HART Voltage at higher current and MORE current source have LESS Voltage available at higher current. The SVI II ESD is unique in that it requires LESS Voltage at higher current which compliments the characteristic of the source requiring only 9.6 V at 20 mA.

NOTE Improperly or inadequately grounded installations can cause

noise or instability in the control loop. The internal electronic components are isolated from ground. Grounding the case is unnecessary for functional purposes but grounding the case may be necessary to conform to local codes.

devices require MORE

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Page 78

Powering Up the SVI II ESD

Verify the wiring and connections and then connect the current source.

NOTE For hazardous location installation refer to the Masoneilan SVI II

Connecting a Power Source

Depending upon the configuration of the SVI II ESD, powering up the unit consists of connecting to the 4-20 mA current source or the 24 VDC power source.

WARNING This process can cause the valve to move. Before proceeding

NOTE When an SVI II ESD is turned on it is advisable to apply the air

ESD Quick Start Guide (GEA19520 or PN 055201359-999-0000).

ensure the valve is isolated from the process. Keep hands clear from moving parts.

supply before applying the electrical input signal.

Powering Up the ASD Configuration

The ASD, or Analog Safety Demand, configuration uses a 4 - 20 mA current source for power.

CAUTION Use of a low impedance voltage source damages the SVI II ESD.

To power up the ASD configuration of the SVI II ESD:

1. Loosen the four (4) cover screws and remove the cover of the SVI II ESD.

2. Connect the +⁄- terminals of the current source to the 4 - 20 mA IN connector (on the terminal board). The current source + must connect to the terminal board connector +, and the same for -. See Figure 54 on page 81.

3. Reinstall the cover and display.

4. Adjust current to 20 mA. On initial power up of a newly installed SVI II ESD, the PST controller starts up in SETUP mode using the default factory-installed instrument parameters. Once calibrated and configured and set to NORMAL, the PST controller cycles through the NORMAL cycle menu and the following values appear:

The current source must be a true high impedance current limiting device. A proper current source explicitly enables adjustment of the current in mA, not Volts.

78 | =GE Oil & Gas

 PRES: Pressure - unit of measurement and value

Page 79

 SIGNAL

 POS (Position)

An exclamation point (!) appears in the display’s top left corner to indicate that further instrument status is available.

Powering Up the DSD Configuration

The DSD, or Discrete Safety Demand, configuration uses a 24 VDC power source.

To power up the DSD configuration of the SVI II ESD:

1. Loosen the four (4) cover screws and remove the cover of the SVI II ESD.

2. Connect the +⁄- terminals of the 24 VDC power source to the 24 VDC ESD IN connector (on the terminal board). The voltage + must connect to the terminal board connector +, and the same for -. See Figure 55 on page 82.

3. Reinstall the cover and display.

4. Turn on the voltage source. On initial power up, of a newly installed SVI II ESD, the PST controller runs in SETUP mode using the default instrument parameters installed at the factory. Once calibrated and configured and set to NORMAL, the PST controller cycles through the NORMAL cycle menu and the following values appear:

 PRES: Pressure - unit of measurement and value

 SIGNAL

 POS (Position)

An exclamation point (!) appears in the display’s top left corner to indicate that further instrument status is available.

Powering Up the A/DSD Configuration

The A/DSD, or Analog/Discrete Safety Demand, configuration uses both a 4 - 20 mA current source (for the unit) and a 24 VDC source (for the safety trip) for power.

CAUTION Use of a low impedance voltage source damages the SVI II ESD.

To power up the SVI II ESD:

1. Loosen the four (4) cover screws and remove the cover of the SVI II ESD.

The current source must be a true high impedance current limiting device. A proper current source explicitly enables adjustment of the current in mA, not Volts.

3. Reinstall the cover and display.

4. Adjust current to 20 mA.

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5. Connect the +⁄- terminals of the 24 VDC power source to the 24 VDC ESD IN connector (on the terminal board). The voltage source + must connect to the terminal board connector +, and the same for -. Figure 56 on page 82.

6. Reinstall the cover and display.

7. Turn on the voltage source. On initial power up of a newly installed SVI II ESD, the PST controller runs in SETUP mode using the default factory-installed instrument parameters. Once calibrated and configured and set to NORMAL, the PST controller cycles through the NORMAL cycle menu and the following values appear:

 PRES: Pressure - unit of measurement and value

 SIGNAL

 POS (Position)

An exclamation point (!) appears in the display’s top left corner to indicate that further instrument status is available.

NOTE The safety function of the SIF (shutdown of the valve on demand)

must be tested after installation.

Checking the Electronic Module Connections

WARNING Do not remove the instrument cover or connect to an electrical

circuit in a Hazardous Area unless the power is disconnected.

All connections to electronic module in the SVI II ESD are made through the terminal board. There are three versions of the terminal board dependent upon which configuration the SVI II ESD you have; ASD, DSD, or A/DSD. The SVI II ESD terminal board has a terminal block with cage clamp connectors. Confirm that all applicable connections to the electronics module connectors are correct. Not all options are available for every model. Refer to Table 8 for available functionality.

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Page 81

Table 8 SVI II ESD Models and Functionality

Display

Process Variable

Position Retransmit

Configuration Lock Jumper

4- 20 mA Input Signal

Output Switch SW #1

Output Switch SW #2

I/O ON SVI II ESD Usage

SVI II ESD

ASD Analog Safety

Demand

SVI II ESD

DSD Discrete Safety

Demand

SVI II ESD

A/DSD Analog Power

with Discrete Safety

Demand

Analog In (4-20 mA) Safety Trip Signal +

HART

+ Analog PST

ESD In

Not Used Safety Trip Signal +

(0-24 VDC)

SW1

Not Configurable Not Configurable Not Configurable

Not Used Device Power + Analog

PST + HART

Safety Trip Signal

HART

(1 A, 24 VDC)

SW2

Configurable Status Configurable Status Configurable Status

(1 A, 24 VDC)

DI (switch input) Unlatch (1) Unlatch (1) Unlatch (1)

PV (1-5 VDC) Read Tight Shutoff Flow

(2)

Local LCD / Buttons ESD Status

Local PST

Read Tight Shutoff Flow (2)

ESD Status Local PST

Read Tight Shutoff Flow (2)

ESD Status Local PST

(1) Latching is software configurable.

(2) 1 - 5 VDC variable is sent using HART

command #3 as the variable TV.

Figure 54 Connections to ASD Electronics Module (via Terminal Board)

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Figure 55 Connections to DSD Electronics Module (via Terminal Board)

Display

Process Variable

Position Retransmit

Configuration Lock Jumper

24VDC IN Input Signal

Output Switch SW #1

Output Switch SW #2

Display

Process Variable

Position Retransmit

Configuration Lock Jumper

4- 20 mA Input Signal

Output Switch SW #1

Output Switch SW #2

Digital Signal

24VDC IN Input Signal

82 | =GE Oil & Gas

Figure 56 Connections to A/DSD Electronics Module (via Terminal Board)

Page 83

Making Connections to the Terminal Board

Each terminal block on the terminal board has a cage clamp connector. One side of the connector has the actual connection for the wire, with a lever at the top. If there is an option present that is not properly connected to the terminal board or if adding a new option, connect the wires from the option as follows:

1. If the option’s wires have not been stripped, strip the insulation at the end of wires.

2. Locate the correct terminal block on the terminal board (see Figure 54 on page 81).

3. Push the lever back at the top connector until you see the opening for wire insertion. The connectors are spring activated and may require a lot of pressure to move the lever.

4. Insert the wire into the opening and release the lever.

NOTE Improperly or inadequately grounded installations can cause

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SVI II ESD Maintenance

Repair and Replacement

Repairs may be made only by the factory authorized personnel trained to repair Safety Devices.

CAUTION When working on safety rated equipment appropriate risk

1. A conservative approach is taken in estimating the service interval for the digital valve controller in Safety Instrumented Systems. For SIS applications, perform preventive maintenance on the SVI II ESD after five years from the shipment date, if the average daily ambient temperature is below 60°C (140°F). Where ambient temperature exceeds 60°C (140°F) for extended periods, reduce this maintenance interval based on plant experience.

2. SVI II ESD preventive maintenance consists of replacing gaskets, O-rings in the device and a visual inspection of moving components to verify satisfactory condition. Following maintenance, the SVI II ESD must be reinstalled on the valve actuator and calibrated per the procedures. After calibration, validate the SVI II ESD functional safety. All maintenance procedures must be performed only by the factory authorized personnel trained to repair Safety Devices.

reduction safety measures must be in place.

3. If alarms or alerts are detected during operation, maintenance or periodic inspection and test, immediately take corrective action according to the troubleshooting and repair procedures given in the Instruction Manual.

4. The tools required for repair of the SVI II ESD are also listed in the SVI II ESD Instruction Manual, EW5000-ESD.

Factory Notification

Report any failures detected that compromise functional safety to the factory. Contact your local the factory service representative. Sales Office locations are listed on the back cover of this document.

NOTE GE does not assume responsibility for the selection, use, or

maintenance of any product. Responsibility for proper selection, use of any GE product remains solely with the purchaser and end-user. The SVI II ESD requires recertification, which must be performed by factory authorized personnel trained to repair Safety Devices.

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The contents of this publication are presented for informational purposes only, and while

Pneumatic Cover

Cover

Display

every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. We reserve the right to modify or improve the designs or specifications of such products at any time without notice.

Display Cover Removal and Installation

The cover with display (shown in Figure 19) is standard with the SVI II ESD. If you to replace the display cover, follow the instructions below for removal and installation.

Tools Needed for Cover Replacement

 5 mm hex key for the cover

 3 mm hex key for the lanyard

Removing the SVI II ESD Display Cover

To remove the SVI II ESD Display cover:

1. Using a 5 mm Hex key unscrew the four screws around the perimeter of the SVI II ESD cover.

2. Lift the cover off the PST controller.

Figure 57 SVI II ESD Pneumatic and Display Covers

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Installing the SVI II ESD Display Cover

The replacement Display Cover is shipped with a lanyard to prevent the cable (that connects from the display to the Terminal Board) from breaking. Insert the lanyard under the screw in the lower left corner that attaches the terminal board to the SVI II ESD housing.

To install the cover:

1. Install the lanyard and tighten the screw to 5 in/lb.

2. Using a 3mm hex key, remove the screw from the lower left corner, connecting the terminal board to the SVI II ESD housing.

3. Connect the cable from the display into the LCD connector on the terminal board.

4. Ensure that the gasket is in its groove in the housing.

5. Place the cover over the screw mounts.

6. Tighten the four screws with the 5 mm hex key.

7. After installing the new display “Powering Up the SVI II ESD” on page 78

NOTE The cover of the SVI II ESD is a critical component for safety in

Hazardous Areas. To ensure safe operation the flat surfaces of the cover and the housing must be clean and absolutely free of particles or dents. There must be no gap between the housing and cover; torque spec is 50 in/lb.

Ensure that:

1. The gasket is seated in the groove in the housing flange.

2. No wires or retaining cable can be trapped under the cover flange.

3. The flange area is not corroded and the surface is not scarred.

4. The four cover bolts are securely tightened to 50 in/lb.

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Page 87

5. Configuration and

NOTE

Calibration

Overview

This section provides information on SVI II ESD setup and calibration procedures to ensure proper valve positioning.

You should perform setup and calibration procedures in this section before putting the SVI II ESD into operation as the SIF.

SVI II ESD Setup

Pushbuttons and local display are thoroughly described in “Pushbuttons and Local Display” on page 98 of this manual.

Using the Pushbuttons and Display

When configuring or calibrating a valve equipped with SVI II ESD, using the pushbutton display, the following steps are recommended:

1. Change mode to Manual mode.

2. Examine and adjust all Configuration items.

3. Enter Calibration mode.

4. Run Stops to automatically calibrate stroke.

5. Run Auto Tune to set dynamic response.

6. Examine device Status.

7. Introduce manual set point changes to verify dynamic performance.

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Configuration

To perform configuration and calibration you can use either pushbutton display, HART® handheld communicator, HART “Pushbuttons and Local Display” on page 98 or the SVI II ESD Help for instructions.

The following section describes configuration and calibration procedure using optional local display and pushbuttons.

WARNING These procedures can cause the valve to move. Before proceeding

Host with the DD loaded, or ValVue ESD software. Refer to

be sure that the valve is isolated from the process. Keep hands clear from moving parts.

Configuration with Pushbutton Display

To change the current configuration parameters:

1. After power up, if SVI II ESD is not in NORMAL mode, switch to NORMAL mode. The display alternates between POS and SIGNAL indicating NORMAL mode.

2. Press + to until MANUAL appears.

3. Press * to select MANUAL mode. The display alternates between POS –M and SIG indicating MANUAL mode.

4. Press * and SETUP appears.



5. Press * again and

6. Press * to access CONFIGuration menu.

7. Set the configuration parameters: Air Action, Air Pressure Units and Language by:

a. Pressing * to access and change the parameter.

b. Pressing + to move to the next parameter.

8. Press + to return to SETUP.

9. Press + to return to NORMAL mode.

CONFIG appears.

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Viewing Configuration Data

To view SVI II ESD configuration data:

1. Access VIEW DATA menu from MANUAL menu by pressing the +.

2. Press * to examine configuration. Table 9 lists the menu items.

Table 9 VIEWDATA Settings

Configuration

Parameter

Air Action ATO ATC

Air Pressure Units PSI BAR KPA

Language ENGLISH FRENCH, GERMAN, ITALIAN, PORTUGUESE,

Typical Setting Optional Setting

SPANISH, JAPANESE (simplified)

3. Press + to scroll through and observe the factory configuration.

4. Press + until MANPOS appears and press *. The adjustment screen appears.

5. Stroke the valve open by holding + down. The rate of set point change is slow to begin, but increases speed while the + is pressed.

6. Stroke the valve to several values.

7. Verify the action is as desired.

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ATO

Setup

Air to....Menu

CONFIGuration Menu

ATC

PSI

BAR

KPA

ENGLISH

FRENCH

+/-

Pressure Units

Language

Air to Menu

CONFIG

Language

Pressure

Menu Units

Select display language.

Select display units for pressure.

Select Air To Open (ATO) or Air To Close (ATC). Must match the actuator exactly.

Press * to select option. Press + or - to accept and proceed to next menu item.

SPANISH

PORTUGUESE

JAPANESE

ITALIAN

GERMAN

See Figure 62 on page 102 for full menu

Figure 58 Configuration Pushbutton Guide

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Calibration with Pushbutton Display

CAUTION Pilot Trim Valve Applications require the use of the Manual Stop

calibration procedure. Do not run Find Stops or ValVue ESD Setup Wizard on valves with Pilot Trim or damage to the valve occurs.

NOTE Always perform configuration before running calibration

functions.

In order to calibrate SVI II ESD using the pushbutton display, it must be in SETUP mode. To calibrate the SVI II ESD:

1. On power up, if SVI II ESD is not in NORMAL mode, switch to NORMAL mode. Display alternates between POS and SIGNAL indicating NORMAL mode.

2. Press + to access MANUAL mode and MANUAL appears.

3. Press * to select the MANUAL mode and the display alternates between POS –M and SIG indicating MANUAL mode.

4. Press * and SETUP appears.

5. Press * and

6. Press + to display



CONFIG appears.



CALIB.

7. Select CALIB by pressing *. STOPS appears.

8. Press * to activate the Find Stops calibration procedure. The valve moves full open and back to full closed. Observe all warnings.

9. Press * to cause the valve to stroke and to automatically calibrate valve travel.

10. Wait until STOPS procedure finishes, press + twice until TUNE appears.

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Calibration using Auto Tune

WARNING DO NOT perform STOPS while the valve is controlling the process.

To auto tune the SVI II ESD using the pushbutton display:

1. Press * to begin Auto TUNE procedure and TUNE appears. This takes 3 to 10 minutes and strokes the valve in large and small steps to set PID parameters for best positioning response. When auto TUNE proceeds, numerical messages are displayed, indicating the procedure is working.

2. When auto TUNE is complete, TUNE appears.

Valve must be isolated from the process before starting calibration. Calibration procedure strokes the valve over it’s full range.

DO NOT perform AUTO TUNE while the valve is controlling the process.

3. Press + repeatedly until

4. Press * to return to SETUP menu and the current calibrator.

5. Stroke the valve through its range to verify that movement is as needed.

6. Press + to return to SETUP.

7. Press + to return to NORMAL mode.

Correct for Over Travel

WARNING While Calibration and Configuration are in progress the valve

On some valves full travel is larger than nominal valve travel and it may be desirable to have the reported 100% position corresponding to nominal travel, rather than the full stroke. The STOP OP option allows you to perform this correction. Use this procedure if a correction has to be made.

1. From CALIB press * to display Stops.



SETUP appears.



CALIB appears. The valve moves to the value set by

moves. Keep hands clear. Isolate the valve from the process.

92 | =GE Oil & Gas

2. Press + to display STOP OP.

3. Press * to move valve to the 100% position.

4. Using the + and - buttons, position the valve to the nominal full open position.

5. Press * to accept this position as the new 100% position.

Page 93

Adjust Input Signal Range

SIG LO displays the input signal that corresponds to the full closed (ATO) or full open (ATC) valve position.

1. In SIG LO, if the displayed value is:

 Correct, press + to advance to the next item and move to step 4.

 Not correct, press * to display SIG LO value.

2. Use + and – buttons to change the value.

3. Press * to return to menu and move to next item. SIG LO value must be between 3.8 and

14.0 mA.

SIG HI displays input signal that corresponds to valve full open, ATO, or valve full closed, ATC position.

4. If SIG HI is:

 Correct, press + to advance to the next item.

 Not correct, press * to display SIG HI value.

5. Use + and – buttons to change value.

6. Press * to return to menu and move to next item. SIG HI value must be between 10.0 and

20.2 mA. SIG HI must be greater than SIG LO by, at least, 5 mA. Positioner Calibration is now complete.

7. At -› MAN, press * to return to the MANUAL mode. MAN POS appears.

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Configuring with ValVue ESD

ValVue ESD provides advanced diagnostic, maintenance capabilities and complete calibration and configuration for SVI II ESD. The software also performs scheduled and on demand Partial Stroke Testing (PST), performs valve diagnostics (proof testing) and provides results in graphic, informational and historical formats. The software has a database to store test results to compare with future results for predictive maintenance. It is password protected against access to remote instruments. It is set up with different administration level features.

ValVue ESD is the most complete and easiest to use configuration tool. ValVue ESD is delivered with each SVI II ESD. ValVue ESD provides a personal computer interface for configuring and calibrating SVI II ESD. Use of these tools is recommended. See the ValVue ESD On Line Help.

NOTE Never connect ValVue ESD software to an SVI II ESD while

configuring or calibrating using pushbuttons.

Starting ValVue ESD/ESDVue

ValVue ESD creates an icon on your desktop during installation as shown below. Start ValVue ESD by clicking on the icon or activate it by selecting Windows Start\Programs\ValVue

ESD\ValVue ESD.

94 | =GE Oil & Gas

Figure 59 ValVue ESD Icon

Page 95

Check-out with a HART® Handheld Communicator

20.00 mA

Configuration

Lock Jumper

Input Signal

GE DPI620

Connect the HART

Handheld Communicator (HHC) to the SVI II ESD as shown in Figure 60. Refer to Product Manual for HART device.

Communicator supplied with the HART® Communication

Figure 60 SVI II ESD HART

Be sure that configuration lock jumper is in unlock position. When the jumper is in lock position (shorting the two-pin header) the HHC is not allowed to make any changes. However, parameters are readable. If fault messages appear, they must be handled before proceeding with HART

communications. Before communications proceeds all error messages must be cleared. For example, the following message is displayed if the instrument has been serviced and the air is not connected.

NOTE “Process applied to the non-primary variable is outside the

Communicator Connections

operating limits of the field device”

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Proceed with the following steps:

1. Press NEXT

2. Field device has more status available

3. Press NEXT

4. Ignore next 50 occurrences of status?

5. Press YES

6. Change to MANual mode

7. Scroll to line 6 “EXAMINE,” press

->.

8. Scroll down to line 5 read status.

9. Read message.

10. Press OK.

11. Repeat OK to read all messages until the display returns to “read status”.

12. Scroll down to line 6 clear status, press

->.

13. If clear fault codes not completed appears, press OK and read the message (Position Error, for example) or go to the troubleshooting guide.

14. Correct the problem (Is the air supply on?), and then go to clear status until Clear Fault codes Completed appears.

15. Press OK.

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Page 97

6. Using the Digital Interfaces

Overview

This section describes four ways to communicate, configure, and calibrate the SVI II ESD. The SVI II ESD is capable of:

 Annunciating system faults

 Streamlining the safety valve positioning function

 Providing diagnostic information

 Improving precision of process control

 Communicating critical information locally and remotely

The four available communication tools listed below offer increasing levels of functionality.

 Local Display and Push Buttons

 HART

 ValVue ESD

 Any HART

Handheld Communicator

capable Host loaded with the DD for the SVI II ESD

Local Display and Pushbuttons

The most basic and easiest interface is the local pushbutton and display option mounted on the SVI II ESD. It is available at any time and provides immediate local access to most configuration, parameters, calibration procedure, and fault messages. It is approved for use in Explosion Proof and Intrinsically Safe installations in Hazardous Areas.

HART® Handheld Communicator

The HART® handheld communicator is a universally available tool that provides the same accessibility as the local button and display. The HART download configurations, enter alphanumeric messages and set the custom characteristic numerical parameters. The GE DPI620 is approved for Intrinsically Safe use in Hazardous Areas in accordance with SVI II ESD Approvals.

tool has the functionality to upload and

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ValVue ESD

(Select)

(Forward)

(Back)

ValVue ESD combines the power of the PC with the features of SVI II ESD for ease of use and automation of positioner operation giving full access to all data. ValVue ESD is provided with all SVI II ESD positioners and is recommended for set up, service and maintenance where a PC or laptop is permitted. See “Configuring with ValVue ESD” on page 94 for further information.

Pushbuttons and Local Display

Local interface to the SVI II ESD consists of the LCD alphanumeric display and pushbuttons. The SVI II ESD can be controlled locally through the device-mounted pushbuttons and digital display, shown in Figure 61 on page 98. Using the display you can read the input signal, valve position, and actuator pressure. The display switching sequence from one variable to the next is every 1.5 seconds.

Using pushbuttons you can change operating modes at any time and step through a menu structure to perform manual operation, calibration, configuration, and monitoring functions. SVI II ESD provides internal diagnostics and if a fault is detected it appears on the display. ValVue ESD provides advanced diagnostic functions. The pushbuttons do not support ValVue ESD advanced diagnostics functions.

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Figure 61 SVI II ESD Display

Page 99

Table 10 lists menus items and functional descriptions, including parameters if applicable.

Table 10 Pushbutton Display Menus

Pushbutton Menu Function/Parameters

NORMAL Runs SVI II ESD in normal operating mode, displays position, signal and pressure.

MANUAL Executes manual mode in which the valve does not respond to input signal and you can

adjust position manually. In MANUAL mode the valve responds to the Trip signal in addition to responding to HART

SETUP SETUP menu provides access to lower level setup menus; configuration (CONFIG), calibration

(CALIB) and PST configuration.

CONFIG Using CONFIG (configuration) menu you can set the following parameters: ATO/ATC, Pressure

units, display language.

CALIB Using CALIB (calibration) menu you can calibrate SVI II ESD by running STOPS (find stops) and

TUNE (autotune) functions.

PST CONF Using PST CONF (PST configuration) menu you can configure the following PST parameters:

TRAVEL (adjustable from 0 to 100% of travel rating), PMIN (minimum allowed pressure during PST), MAX TIME (maximum allowed time in seconds for partial stroke), PST SPEED (the valve travel speed in% travel per second).

. MANUAL mode menu provides access to SETUP.

VIEW DATA The VIEW DATA menu displays the parameters set in CONFIG and PST CONF.

VIEW ERR The VIEW ERR menu displays all current errors.

CLR ERR The CLR ERR menu allows you to clear current errors, one at a time.

RUN PST The RUN PST menu executes PST (Partial Stroke Testing)

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Accessing Pushbuttons

The local pushbuttons are located behind a hinged cover, directly below the display window. To open the cover loosen the screw and swing the cover down. Always re-fasten the cover after use to protect pushbuttons from environmental contamination.

NOTE When an exclamation mark (!) appears in the SVI II ESD display

The three pushbuttons perform the following functions:

window, it indicates that there is instrument status available.

 Left Button - Marked with

*, selects or accepts the value or parameter option currently

displayed.

 Middle Button - Marked

–, moves back through the menu structure to the previous item

in the menu or decrements the currently shown value in the digital display. Holding down the button causes the value to decrease at a faster rate.

 Right Button - Marked

+, moves forward through the menu structure to the next menu

item, or increments the currently shown value in the digital display. Holding down this button causes the value to increase at a faster rate.

Pushbutton Locks and Configuration-Lock Jumper

Before performing any configuration or calibration functions using the local display you must first ensure that the pushbuttons are placed in unlocked mode using ValVue ESD. The positioner is factory set in unlocked mode. See ValVue ESD On Line Help for more details.

The SVI II ESD offers several security levels. It may be desirable, after initial setup, to lock the pushbuttons so that the SVI II ESD parameters cannot be inadvertently changed by buttons. Several levels of software modifiable pushbutton locks are provided.

Table 11 Pushbutton Lock Security Level

Level Access

Security Level 3 Allow Local Buttons: Buttons on SVI II ESD are fully enabled.

Security Level 2 Lock Out Local Calibration and Configuration: Use the buttons to perform operations in normal

operating mode and manual mode. Do not go to configure or calibrate mode.

Security Level 1 Lock Out Local Manual: Examine variables in normal operating mode but do not put valve in

manual operating mode. Access to calibrate or configure modes is not available.

Security Level 0 Lock Out All Buttons: Buttons are disabled (level 0).

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