Rosemount Rex SIL 2 Safety Manuals & Guides

Safety Manual
308020EN, Edition 1 June 2007
Rosemount TankRadar Rex
Safety Manual For Use In Safety Instrumented Systems
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308020EN, Edition 1 June 2007
Rosemount TankRadar Rex
Safety Manual Rosemount TankRadar Rex
First edition
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Copyright
© June 2007
Rosemount Tank Radar AB
Rosemount TankRadar Rex
Copyright © June 2007 Rosemount Tank Radar AB
Spare Parts
Any substitution of non-recognized spare parts may jeopardize safety. Repair, e.g. substitution of components etc, may also jeopardize safety and is under no circumstances allowed.
Rosemount Tank Radar AB will not take any responsibility for faults, accidents, etc caused by non-recognized spare parts or any repair which is not made by Rosemount Tank Radar AB.
308020EN, Edition 1
June 2007
WARNING
Do not open the Integrated Junction Box JBi when the circuit is alive.
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308020EN, Edition 1 June 2007
Rosemount TankRadar Rex

Contents

Content s
1. SCOPE AND PURPOSE OF THE SAFETY MANUAL . . . . . . . . . . 1
2. R
3. S
EFERENCE DOCUMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . 2
COPE OF THE PRODUCT . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 PURPOSE OF THE PRODUCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 ASSUMPTIONS AND RESTRICTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.3 FUNCTIONAL SPECIFICATION OF THE SAFETY FUNCTIONS . . . . . . . 3
3.4 PARAMETERS RELATED TO SAFETY FUNCTIONS . . . . . . . . . . . . . . . . 7
3.5 HARDWARE AND SOFTWARE CONFIGURATION . . . . . . . . . . . . . . . . . 12
4. INSTALLATION AND CONFIGURATION. . . . . . . . . . . . . . . . . . 13
4.1 CONFIGURATION WITH ONE RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2 CONFIGURATION WHEN USING TWO RELAYS IN SERIES . . . . . . . . . 17
4.3 VERIFICATION OF THE SAFETY FUNCTION . . . . . . . . . . . . . . . . . . . . . 20
4.4 WRITE PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5. PROOF TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.1 TRIGGERING THE RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.2 HAND DIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.3 VERIFICATION OF THE RELAY FUNCTION . . . . . . . . . . . . . . . . . . . . . . 23
5.4 REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6. TERMS AND DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Appendix FMEDA and Proven-in-use Assessment . . . . . . .27
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Rosemount TankRadar Rex
Contents
308020EN, Edition 1
June 2007
ii
308020EN, Edition 1 June 2007
Rosemount TankRadar Rex
Chapter 1 Scope and Purpose of the
Safety Manual

1. Scope and Purpose of the Safety Manual

The purpose of the safety manual is to document all the information, relating to TankRadar Rex 3900 Series, which is required to enable the integration of TankRadar Rex into a safety­related system, in compliance with the requirements of IEC
61508.
1
Rosemount TankRadar Rex
Chapter 2 Reference Documents

2. Reference Documents

IEC 61508
IEC 61511
Rosemount TankRadar Rex Installation Manual, Ref. no. 308014EN
Rosemount TankRadar Rex Service Manual, Ref. no. 308012EN
Rosemount TankRadar Rex Special Safety Instruction, Ref. no. 308016E
TankMaster WinSetup User’s Guide, Ref. no. 303027EN
Rosemount TankRadar REX Technical Description, Ref. no. 703010EN.
308020EN, Edition 1
June 2007
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308020EN, Edition 1 June 2007

3. Scope of the Product

3.1 Purpose of the Product

The Rosemount TankRadar Rex 3900 Series is designed for high performance level gauging in various types of storage tanks. Temperature sensors, remote display unit, water level sensors, pressure sensors, and other devices can be connected. Two relays are available for alarm indication and overfill and dry run protection.

3.2 Assumptions and Restrictions

Install the TankRadar Rex according to the instructions in this document. The Rosemount TankRadar Rex Installation Manual and the Rosemount TankRadar Rex Special Safety Instruction provide further instructions for a safe installation.
Rosemount TankRadar Rex
Chapter 3 Scope of the Product
Note that the TankRadar Rex is not safety-rated during maintenance work, configuration changes, or other activity that affects the Safety Function. Alternative means should be used to ensure process safety during such activities.
False echoes within the radar beam from flat obstructions with a sharp edge may lead to a situation where the TankRadar Rex can no longer be used for safety related functions with the listed failure rates, Safe Failure Fraction and PFD
. However, reduced proof
AVG
test intervals can help to detect such unwanted causes. Operating conditions are available in the TankRadar Rex
Technical Description, ref no. 703010EN.

3.3 Functional Specification of the Safety Functions

The Safety Function is based on the relay output (one or two relays) used as the primary safety variable for overfill and dry run protection. The relay function is configured to activate the alarm mode at a preset product Level or product Ullage (Ullage is the space between the top of the tank and the product surface).
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Rosemount TankRadar Rex
Chapter 3 Scope of the Product
TankRadar Rex is equipped with two cable outputs for intrinsically safe and non-intrinsically safe connections, respectively. Wires are clearly marked with numbers and designation of wires is shown on a printed plate at the cable outputs. The transmitter can also be equipped with an Integrated Junction Box (JBi).
W1 1 is for the relays, the TRL/2 Bus, and the non-intrinsically safe power supply.
W12 is for the intrinsically safe connection of Data Acquisition Unit (DAU), Remote Display Unit RDU40, analog inputs, and temperature sensors.
308020EN, Edition 1
June 2007
Integrated Junction Box (JBi)
W12 Intrinsically safe connections
W11 Non-Intrinsically safe connections
Figure 1. Electrical connections on the TankRadar REX.
Connect to the relay ports on the W11 side, or to the X11 terminal if the TankRadar REX with Integrated Junction Box JBi is used:
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308020EN, Edition 1 June 2007
Rosemount TankRadar Rex
Chapter 3 Scope of the Product
K1A K1B K2A K2B
relay K1relay K1relay K1
relay K2
Figure 2. Connecting to the relay ports via Integrated Junction
Box (JBi).
Note! Depending on system configuration one or two relays are available.

3.3.1 Safety Function Using One Relay

The Safety Function is based on the relay output (relay K1 or relay K2) used as the primary safety variable for overfill and dry run protection. The Safety Function requires that the relay output is configured as Normally Open. Normally Open refers to the contact position when the relay is de-energized. This is also referred to as the Alarm state. The terminology for Normally Open can be summarized as described in Table 1 below:
Normally Open
Open Closed
De-energized Energized
Not active Active
Alarm (reset) Normal
Table 1. Relay terminology for relays configured as Normally
Open.
See the TankRadar REX Installation Manual for information on how to configure the Relay Output Card (ROC) for operation in Normally Open mode.
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Rosemount TankRadar Rex
Chapter 3 Scope of the Product

3.3.2 Safety Function Using Two Relays in Series

This Safety Function is based on the two relay outputs coupled in series used as the primary safety variable for overfill and dry run protection. The Safety Function requires that the two relay outputs are configured as follows: one relay Normally Open and the other relay Normally Closed.
The default setting is Normally Open for both relays K1 and K2. See the TankRadar REX Installation Manual for information on how to configure the Relay Output Card (ROC) for operation in Normally Open or Normally Closed mode.
The relays are configured in such manner that when the set point (e.g. overfill) is reached one of the relays will "pull" while the second relay will "release". Below the set point (normal operation) the relays will be in the positions as shown in Figure 3:
308020EN, Edition 1
June 2007
A
Relay K1
Relay K2
Figure 3. A. Relay positions under normal operation.
B. Wiring diagram for Safety Function using two relays cou­pled in series.
B
The system state is given by the states of the two relays according to Table 2:
System state
Normal Energized De-energized Alarm De-energized Energized
Relay K1
(Normally Open)
Relay K2
(Normally Closed)
Alarm Energized Energized Alarm De-energized De-energized
Table 2. System state versus relay state with Safety Function using
two relays coupled in series.
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