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Hytork XL Pneumatic Actuator
SIL Safety Manual
SIL Safety Manual
DOC.SILM.HXL.EN Rev. 0
May 2015
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Hytork XL Series
DOC.SILM.HXL.EN, Rev. 0
Table of Contents
Section 1: Functional Specification ���������������������������������������1
Section 2: Configuration of the Product �������������������������������� 2
Section 3: Service Condition Limitations ������������������������������� 3
Section 4: Expected Lifetime �������������������������������������������������4
Section 5: Failure Modes and Estimated Failure Rates �����������5
Section 6: Installation and Site Acceptance Procedure ����������6
Table of Contents
May 2015
Section 7: Periodic Test and Maintenance Requirements ������� 7
7.1 General ...................................................................................................... 7
7.2 Full-Stroke Test .......................................................................................... 7
7.3 Partial-Stroke Test ...................................................................................... 8
7.4 Proof Test and Periodic Maintenance .......................................................... 8
Section 8: Hardware Fault Tolerance ������������������������������������� 9
Section 9: Classification ������������������������������������������������������ 10
Section 10: Safe Failure Fraction �������������������������������������������11
Section 11: Mean Repair Time ����������������������������������������������12
ITable of Contents
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Section 1: Functional Specification
May 2015
Section 1: Functional Specication
The safety function for Hytork XL pneumatic actuator is dened as follows:
Double-Acting Scenario:
a. When an unsafe condition is detected in a plant by a process sensor, the
controller, via actuator control system, drives the Actuator to close the
shut-down valve, depressurizing (if under pressure) the Opening side of
the actuator and pressurizing the Closing side of the actuator.
b. When an unsafe condition is detected in a plant by a process sensor, the
controller, via actuator control system drives the Actuator to open the
blow-down valve, depressurizing (if under pressure ) the Closing side
of the pneumatic actuator and pressurizing the Opening side of the
pneumatic actuator.
Single-Acting Scenario:
a. When an unsafe condition is detected in a plant by a process sensor, the
controller, via actuator control system drives the Actuator to rotate with
sufcient torque to move a valve to its fail-safe state when hold-position
air pressure is released.
The Hytork XL brand Actuator Selection Procedure provides functional denition with
specics on input variables and performance.
SIL Safety Manual
DOC.SILM.HXL.EN, Rev. 0
In any case, the choice of the safety function to be implemented is responsibility of the
system integrator.
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Functional Specification
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SIL Safety Manual
DOC.SILM.HXL.EN, Rev. 0
Section 2: Configuration of the Product
Section 2: Conguration of the Product
The Hytork XL are pneumatically operated actuators designed to operate Ball / Plug /
Buttery valves, automation of louvers and dampers & automation of any quarter-turn
mechanism. Both the double-acting and single-acting (spring-return) versions of the
Hytork XL pneumatic actuators are designed in such a way that there are no moving parts
on the outside (with the exception of the position indicator). This makes them safe, easy to
install and virtually maintenance free.
For further details about actuator congurations, please refer to the Hytork XL product
data sheets, Safety guide and Installation, Operation and Maintenance manual.
NOTE:
This product is only intended for use in large-scale xed installations excluded from the
scope of Directive 2011/65/EU on the restriction of the use of certain hazardous substances
in electrical and electronic equipment (RoHS 2).
May 2015
Configuration of the Product
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AB
A
B
A
B
A
B
Pistons Pistons
Pinion
Section 3: Service Condition Limitations (Limitation of Use)
May 2015
SIL Safety Manual
DOC.SILM.HXL.EN, Rev. 0
Section 3: Service Condition Limitations
(Limitation of Use)
The operating capabilities are listed below:
• Maximum Operating Pressure:
— Pneumatic Service
— Up to 8 Barg (116 PSIg)
• Ambient Temperature:
Temperature extremes require different solutions to maintain actuator operational
integrity and reliability. For each Hytork XL actuator is available in three different
temperature executions.
— -20°C to +100°C (-4°F to +212°F) Standard temperature
— -20°C to +120°C (-4°F to +248°F) High Temperature
— -40°C to +100°C (-40°F to +212°F) Low Temperature
• Torque Output Range:
— Double-Acting Hytork XL actuators, requiring pressure to rotate in either
direction, are available with a torque range between 10 Nm
(83 lbf.in) and 4,702 Nm (47,250 lbf.in)
— The Hytork XL spring-return models require pressure in only one direction
of travel and are suitable for air-fail close and air-fail to open applications
without modication. These models are available with a spring end torque
between 4 Nm (32 lbf.in) and 1525 Nm (13,494 lbf.in)
• Safety Function:
For spring-return models, the safety function is self-evident performed by the
springs. The safety function of double-acting models shall be performed by the
A-port. The failure rates in Section 5 are valid only for this conguration.
Figure 1 Use the A-Port for Safety Related Systems on Double-Acting Actuators
Assembly Code: CW Assembly Code: CC
= Safety Function is = Safety Function is
Counterclockwise Rotation Clockwise Rotation
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Service Condition Limitations (Limitation of Use)
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SIL Safety Manual
DOC.SILM.HXL.EN, Rev. 0
Section 4: Expected Lifetime
Actuator lifetime (for which failure rates indicated in Par. 5 are ensured) strongly depends
on operating conditions.
For normal service conditions, Hytork XL actuators can be in good conditions also after
more than 10 years with planned minimum maintenance. Normal working life is the
number of cycles as dened in Table 1 of EN 15714-3. Hytork XL carry a warranty period of:
• 18 months after delivery if properly stored in conditions that we declare or
• 12 months after installation on site.
Section 4: Expected Lifetime
May 2015
Expected Lifetime
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Section 5: Failure Modes and Estimated Failure Rates
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SIL Safety Manual
DOC.SILM.HXL.EN, Rev. 0
Section 5: Failure Modes and Estimated
Failure Rates
Table 1� Failure Rates – Hytork XL Pneumatic Actuator
Failure Category
Fail Safe 96 0
Fail Dangerous Undetected 302 397
No Effect 1662 1762
The failure rates for the Hytork XL pneumatic actuator when performing partial valve
stroke testing are listed in the table below:
Table 2� Failure Rates – Hytork XL Actuator with partial valve stroke testing
Failure Category
Fail Safe 96 0
Fail Dangerous Detected 178 207
Fail Dangerous Undetected 124 190
No Effect 1662 1762
Spring-Return Double-Acting
Spring-Return Double-Acting
Failure Rate (in FIT)
Failure Rate (in FIT)
NOTICE
No internal diagnostics is included in the device. These values are valid when taken in
account the maintenance interval and procedure described in Section 7, and for the
expected lifetime dened in Section 4.
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Failure Modes and Estimated Failure Rates
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SIL Safety Manual
DOC.SILM.HXL.EN, Rev. 0
Section 6: Installation and Site Acceptance Procedure
Section 6: Installation and Site
Acceptance Procedure
Any necessary installation and site acceptance procedures are discussed in the Hytork XL
actuators Installation, Operation and Maintenance manual. The Installation, Operation
and Maintenance manual denes exercising of the actuator after installation and denes
testing after maintenance.
May 2015
Installation and Site Acceptance Procedure
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Section 7: Periodic Test and Maintenance Requirements
May 2015
Section 7: Periodic Test and
Maintenance Requirements
7�1 General
Please consider that the information in this paragraph are relevant only in regards of
Reliability Tests; please refer to Doc. Installation, Operation and Maintenance manual for
detailed information about product maintenance, handling and storage.
Diagnostic tests may be made to increase the system reliability (Full-Stroke or PartialStroke Test).
“On site” tests depend on Project/Plant facilities/requirements; however, a functional test
must be executed on site, prior actuator operation.
SIL Safety Manual
DOC.SILM.HXL.EN, Rev. 0
7�2 Full-Stroke Test
The “Full-Stroke Test” (“On-line”) must be performed to satisfy the PFD
probability of failure on demand) value.
The full-test frequencies will be dened by the nal integrator in relation to the dened SIL
level to achieve.
• Procedure:
— Operate the Actuator/Valve assembly for No. 2 open/close complete
cycles with complete closing of the valve.
— Verify the Correct performing of open – close manoeuvre (for example,
check locally, or automatically via Logic solver, the correct movement of
the actuator/valve).
Considering the application of the above described Full-Stroke Test procedure, the “Test
Coverage” can be considered 99%.
(average
AVG
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Periodic Test and Maintenance Requirements
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SIL Safety Manual
DOC.SILM.HXL.EN, Rev. 0
Section 7: Periodic Test and Maintenance Requirements
7�3 Partial-Stroke Test
May 2015
The “Partial-Stroke Test” (“On-line”) can be performed to improve the PFD
A typical partial-stroke value is 15% of the stroke.
The “Partial-Stroke Test” (“On line”) can be performed to satisfy PFD
probability of failure on demand) value.
• Recommended Test Interval = 1 to 3 months.
• Procedure:
— Operate the Actuator/Valve assembly for No 1 open/close cycles 15/20%
of the stroke.
— Verify the Correct performing of partial-stroke operation (for example,
check locally, or automatically via Logic solver, or via the PST system the
correct movement of the actuator/valve till 15/20% of the stroke).
The above parameters to check will depend from the partial-stroke test system available.
Considering the application of the above described Partial-Stroke Test procedure, the
“Diagnostic Coverage” is >90 %.
7�4 Proof Test and Periodic Maintenance
We advise to perform the following checks upon each proof test interval complying with
the rules and regulations of the country of nal installation:
(average
AVG
AVG
value.
• Visually check the entire actuator as well as the control system (where foreseen).
• Ensure there are no leaks on the actuator parts under pressure.
• Check pneumatic connections for leaks. Tighten tube ttings as required.
• Check if manual override (where foreseen) is regular.
• Check if pneumatic lter cartridge (where foreseen) is sound and lter bowl (where
foreseen) has been cleaned properly.
• Check the setting of the relief valves (where foreseen).
• Verify that the power uid supply pressure value is within the required range.
• Remove built-up dust and dirt from all actuator surfaces.
• Inspect actuator paint work for damages to ensure continued corrosion protection.
Touch-up as required in accordance with the applicable paint specication.
• Operate the Actuator/Valve assembly for No 2 open/close complete cycles with
complete closing of the valve.
• Verify the correct performing of open – close operations (for example, check
locally, or automatically via Logic solver, the correct movement of the actuator).
The Installation, Operation and Maintenance manual denes a minimum maintenance
interval after 500.000 cycles for the Hytork XL actuators. This addresses components that
may have age related degradation. When the maintenance interval has elapsed a complete
overhaul of the actuator is required.
Periodic Test and Maintenance Requirements
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Section 8: Hardware Fault Tolerance
May 2015
Section 8: Hardware Fault Tolerance
The HFT of the device is 0.
The requirements of minimum hardware fault tolerance (HFT) according to Tab.6 of IEC
61511-1 have to be observed but, as long as has been performed an assessment report
fully in compliance with IEC 61508 part 1 to7, alternative fault tolerance requirements
have to be considered applicable according to Table 2 of IEC 61508-2 as per par. 11.4.5
of IEC 61511-1.
SIL Safety Manual
DOC.SILM.HXL.EN, Rev. 0
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Hardware Fault Tolerance
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SIL Safety Manual
DOC.SILM.HXL.EN, Rev. 0
Section 9: Classication
The equipment is classied Type A according to IEC 61508-2.
Section 9: Classification
May 2015
Classification
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Section 10: Safe Failure Fraction
May 2015
Section 10: Safe Failure Fraction
SFF=0 without external diagnostic tests.
SFF>0 with external diagnostic tests, carried out according to denition 3.8.7 of IEC 61508-4.
• SFF = 91% with Partial-Stroke Test.
• SFF = 99% with Full-Stroke Test.
The SFF shall be evaluated for the entire nal element sub-system.
The diagnostic test shall be performed considerably more often than the demand of the
safety function.
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DOC.SILM.HXL.EN, Rev. 0
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Safe Failure Fraction
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Section 11: Mean Repair Time
The MRT of the device is 1 hour.
NOTICE
The MRT is estimated considering availability of skilled personnel for maintenance, spare
parts and adequate tools and materials on site (that is, it encompasses the effective time to
repair and the time before the component is put back into operation).
Procedures to repair or replace the Hytork XL actuators are provided in the respective
Installation, Operation and Maintenance manual. Please refer to the Installation, Operation
and Maintenance manual for any tools required for repair and replacement and required
competency of technicians. Maintenance and subsequent test procedures are also covered
in the Installation, Operation and Maintenance manual. Any failures, identied by the enduser during maintenance, repair or proof testing, that potentially impact the functional
safety of the Hytork XL actuators should be reported back to Actuation Technologies
Customer Service Coordinator.
Section 11: Mean Repair Time
May 2015
Mean Repair Time
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World Area Configuration Centers (WACC) offer sales support, service,
inventory and commissioning to our global customers.
Choose the WACC or sales office nearest you:
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For complete list of sales and manufacturing sites, please visit
www.emerson.com/actuationtechnologieslocations or contact us at
info.actuationtechnologies@emerson.com
www.emerson.com/hytork
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