61508 compliance of actuators and life cycle considerations (eng)

2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators · 1

SIL in de praktijk (Functional Safety)23.04.2015 - Antwerpen

SAMSON AGDr. Thomas Karte

61508 Compliance of Actuatorsand Life Cycle Considerations

2015-04-23 SAMSON AG – Dr. Karte - 61508 Compliance of Actuators . 2

� Applied Physics, University of Heidelberg, Germany� Occupied in the Industry since 1985, general area of field instrumentation, later

specialist in pneumatic instrumentation for valves in the process industry� Joined SAMSON in 2003, since then engaged in Functional Safety� Current position: Head of department for Innovation Management and Patents� Member of VDI-GMA 6.13, Functional Safety, DKE 9.14, IEC TC65 – WG 13� Numerous articles and patents

Dr. Thomas KarteSAMSON AG, Frankfurt, Germany

+49 69 4009 2086 [email protected]


� Main task - Change of Material Flows� Increasing Diagnosis and Asset Management Functions

Control Elements - Complex Field Devices


Standard questions and concerns

� Certificate for the device / final element in question

� What is the failure rate

� What is the value for diagnostic coverage

� How can evidence of these numbers be given

� What is the usefull lifetime

� Please, I want to have a SIL 3 valve


IEC 61508 and IEC 61511


Requirement for subcomponent selection


Structure of talk

� Causes of Valve Failures

� Exclusion of Systematic Errors – Manufacturer Measures

� Valve Testing

� Design and Implementation of Automated Testing

� Numerical Rating

� Summary


DIN EN 61511 in a nutshell

Failures

Aviodable in principle Unaviodable in principle

Random failuresSytematic failures

FSM-System

Not avoided

�DiagnosticsFail Safe

Redundancy

Probability CalculationDiagnostics

Fail Safediversely Redundancy

✔✔

Measures sufficient?


Safety Life Cycle to avoid Systematic Errors

�Quelle: DIN EN 61511-1 - Bild 8

Hazard and risk assessment1

Specification of Security? Requirements for the SIS3

Design u.Planung other measures to reduce risk

Design and planning of the SIS4

Decommissioning8

Change7

Operation and maintenance6

Installation, commissioning and validation5

Step 5

Step 4

Step3

Step 2

Step 1

11

Manage-ment andassessmentof thefunctionalsafetyaudits


10


10

Verifi-cation

9

Design and planning the Safety-life-cycle

Allocation of safety functions to protectionlayers2


Main Components of the Final Element

Seat/Disk

Housing

Packing

Seat Ring

Ball

Housing

Globe Valve Ball Valve

SpringMembraneSolenoid valve

Limit Switch

Positioner


Potential Hazards (VDI 2180-5)

� Fatigue (e.g. Metal Bellows Seal)

� Wear from Cavitation / Flashing

� Abrasion (due to material flowing solids)

� Deposits of the Medium

� Aging: Damage caused by exposure to light and heat, Organic materials such as plastics and elastomers

� Chemical Attack: Damage caused by chemical extraction & decomposition processes


Actuator Reliability, Is a Constant Failure Rate Mean ingfull?

Electronics

� Statistical Statements on theReliability

� Controlled Environment� Self-Diagnosis� Methods for accelerated Aging

Mechanics

� Macroscopic, accountable System� Media Influence� Environmental Influence� Long term Effects can´t be Accelerated


1 ISO 9001 Qualified

2 Quality Manual, Primary Process Development

3 Pressure Equipment Directive 97/23/EG

4 Calculation of Pressurized Parts

5 Materials and Supplier Qualification for Pressure Parts

6 Standard Tests to SAMSON- Globe Valves

7 Quality Management installed that keeps track of field performance

8 Adapting the final element to the specific process – valve seizing

Qualifying Procedures - Manufacturer


Fixed R&D Schedule compliant to ISO 9001


Pressure Equipment Directive 97/23/EG


Calculation of Pressurized Parts

�16


Calculation of Pressurized Parts


� Supplier Qualification by SAMSON-Specifications� Minimum Requirement 3.1 - Material Certificate according to DIN EN

10204� 100%-Examination of the Pressure-Bearing parts in the Receipt of Goods

Materials and Supplier Qualification for Pressure Parts


Standard Test to SAMSON Globe Valves


Valve Seizing

� Collection of Customer Data in Accordance with DIN EN 60534-7� Collection of additional Information by Echange with Customers� Creating a TV-SK (special design) if necessary


Valve Seizing –Permissible Flow Velocities

�Supercritical Relaxation

�10bar to 2,5bar

�UVC > Ma1

�Subcritical Relaxation

�10bar to 7bar

�UVC < Ma1

�Critical Relaxation

�10bar to 5bar

�UVC = Ma1


�Quelle: DIN EN 61511-1 - Bild 8

Hazard and risk assessment1

Allocation of safety functions to protectionlayers2

Specification of Security? Requirements for the SIS3

Design u.Planung other measures to reduce risk

Design and planning of the SIS4

Decommissioning�8

Change�7

Operation and maintenance6

Installation, commissioning and validation5

�Stufe 5

Step 4

Step3

Step 2

Step 1

�11

Management andassessmentof thefunctionalsafety audits


�10


�10

Verifi-cation

�9

Safety Lifecycle to Avoid Systematic Errors

• Periodic inspection and testing• Examination during operation• Documentation system failure

Validation

Design and planning the Safety-life-cycle


Safety life cycle at customer side

� Specification of safety requirements

� Selection of suitable components

� Manufacturer declaration

� Valve seizing (fit to the specific process)

� Proven in use statement highly recommended (NE 130)

� Consideration on reliability

� Defined procedures for inspection and testing

� Trained personal

� Documentation of all steps


What is the safety requirement

� The final element shall shut down or open the pipe

� Leakage rate

� Time response

� Keep specifications as wide as possible

� This has major influence on testing and diagnostic


Namur recommendation NE 130 „Proven in use“

• NE 130 provides clear

definition for

„proven in use“

• Instrument

performance for a

specific application is

rated


Failure rates provided by NE 130

� Based an data generated by NE 93

� Survey on a voluntary basis within NAMUR companies

� Applicable for proven in use devices


Process equipment datasheet (VDI 2180 – Part 5)

• Valve seizing process

to adapt to specific

application

• Guided by VDI 2180-5

(example)


How is a Valve Tested

From the Manufacturer

� Items� Leak Test� Pressure Test� Functional Test

In the plant

� Inspection after 61508 (Plant Tour, Visual Inspection) � Functional Test during Non-Operating Times� (Parameters: Function, Closing Time, End Position) � Functional Testing under Load (+ leaks)

Standard requires Testing under Operating Condition s


3730 Positioner

�Solenoid valve, Limit Switches and Positioners Diagnostic Capability in a Housing

�Diagnostics�Automatic Monitoring

during Operation

Automation Options

3738 Intelligent Limit Switch

� Solenoid Valve, Limit Switches

� Certified Safety Function by TÜV

� Diagnostics� Automatic Monitoring during

Operation

Solenoid Valve, Limit Switches


• Suitability for Safety-related Circuits

• Shutdown over 4 mA• Reduced Cabling Costs

Positioner as a Single Automation Component

Safety-related Control Positioner

Position Feedback Positioner, Analogue

Pressure Measurement Positioner, Analogue

Automation Valve Test Positioner

Test Coverage Pneumatic yes


Automated Testing

Result:

� Functional Test � Path-time Diagram� Dead time, run-time� Breakout Force � Exact closed position

ALARM

Reproducible Implementation:

� Valve movement is initiated� Positioner Internal Measurement � of the Valve Motion � Valve Motion is Recorded

Dokumentation:

� Registration of the Event� Numerical Results� Path-time Diagram � Good / Bad Review


Periodic Inspection

Solution:

� Functional Test � Travel-time Diagram� Dead time, Run-time � Breakout Force � Exact Closed Position

ALARM

Rating:

� Ability to move � Breakout Force � Travel-time� Tightness (from closed position)

Implementation:

� Manually triggered� Automatic test without

user interaction


Testing During Operation

As an additional Security Measure, or to check during Operation

Result:� Functional Test � Path-time Diagram� Dead time, Run-time� Breakout Force � Exact Closed Position

ALARM

Rating:

� Ability to move � Breakout Force � Travel-time� Tightness (from closed position)

Implementation:

� Manually or automaticallytriggered

� Automatic test withoutuser interaction


Examination during Operation, Friction Detection


Capture of spurious trips

Result:

� Functional Test� Travel-time Diagram� Dead time, Run-time� Breakout Force � Exact Closed Position

Alarm

Implementation:

� Triggered by valvemovement

� independent datacollection

Rating:

• Ability to move • Breakout Force • Travel-time• Tightness (from closed position)


�Bauformen SIL 2 (Final element 50%)

Safety margin

PRTPFD ⋅= λ2

1

0,0000

0,0025

0,0050

0,0075

0,0100

0 6 12 18 24

Prooftest [month]

PFD

PFD

SIL2-Grenze

λ = 1,14-06 Failure rate (1/hr)

TPR = 1 year Proof Test Intervall

Extended Operation Time by Online Testing


�Bauformen �SIL 2 (Final element 50%)

Safety margin

PRPST TDCTDCPFD ⋅−⋅+⋅⋅= )1(21

21 λλ

PRTPFD ⋅= λ2

1

0,0000

0,0025

0,0050

0,0075

0,0100

0 6 12 18 24

Prooftest [month]

PFD

PFD

PFD PST

SIL2-Grenze

DC = 0,6 Diagnostic coverage

λ = 1,14-06 Failure rate (1/hr)

TPST = 1 month Partial Stroke Intervall

TPR Proof Test Intervall

�PST

Extended Operation Time by Online Testing


2180-3 ( 3.4.1) and IEC 61511

� Analysis of the records is mandatory� Documentation for the operating experience regarding any problems � Potential for improvement: new devices with more favorable properties � Option to extend the proof time

Optimization of Safety Loops

Aus Paul Gruhn, „Safety Shutdown Systems“


Trending


Error Images and Diagnostic Coverage

Component Failure Mode RecognizabilityDiagnostic Possibility

Positioner

Seat/Disk

Corrosioninternal/external

Flow measurement, diagnosis STR, disassembly

acoustic leak sensor, zero offset (driving force, friction)

Fatigue (e.g. Metal Bellows Seal)

not applicable not applicable

Wear from Cavitation / Flashing


acoustic leak sensor, end position trend (Zero Point offset),

(driving force, friction)

Abrasion Flow measurement, diagnosis

STR, disassembly

Deposits of the medium


Aging not applicable not applicable

Chemical Attack not applicable not applicable

mechanical stressFlow measurement, diagnosis

STR, disassembly

acoustic leak sensor, end position trend (Zero Point offset),

(driving force, friction)


Normative Requirements: DefinedProcesses, Documentation, DiagnosticsCoverage

Summary

Safety Life Cycle is supported by state of the art instrumentation

Systematic failures are dominant – as a consequence Safety Life Cycle is the most important isssue

�41


61508 Compliance for Actuators

THANK YOU FOR YOUR ATTENTION !

61508 compliance of actuators and life cycle considerations (eng)

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