KLAY-INSTRUMENTS 8000 Series Guía del usuario

SAFETY MANUAL

SERIES 8000 AND HYDROBAR

Manufactured by:

www.klay.nl

Contents

Nijverheidsweg 5

P.O. Box 13

Tel: +31-521-591550

Fax: +31 -521-592046

7991 CZ DWINGELOO

7990 AA DWINGELOO

The Netherlands

E-mail: [email protected]

Functional safety manual –Series 8000 and Hydrobar

SM-EN-8000/09-2013/01 Page 1

1. Functional Safety............................................................................................................................. 2

1.1 Scope ....................................................................................................................................... 2

1.2 Application area ...................................................................................................................... 2

1.3 Safety function ........................................................................................................................ 2

2. Compliance...................................................................................................................................... 3

2.1 Assumptions ............................................................................................................................ 3

2.2 Product identification.............................................................................................................. 3

2.3 SIL conformity.......................................................................................................................... 3

2.4 Relevant standards.................................................................................................................. 3

3. Safety............................................................................................................................................... 4

3.1 Safety requirements................................................................................................................ 4

3.2 Service Proven ......................................................................................................................... 4

4. Safety-related characteristics.......................................................................................................... 4

4.1 Basics ....................................................................................................................................... 4

4.2 Safe function............................................................................................................................ 5

4.3 Specific characteristics ............................................................................................................ 5

4.4 Time-dependent process of PFDavg.......................................................................................... 5

4.5 Service life ............................................................................................................................... 5

Functional safety manual –Series 8000 and Hydrobar

SM-EN-8000/09-2013/01 Page 2

1. Functional Safety

1.1 Scope

This safety manual applies to measuring systems consisting of Klay Instruments pressure transmitter in a

two wire 4-20 mA loop.

This functionally safety manual applies for:

Series 8000, 8000-SAN, CER-8000, 8000-SAN Cable, Hydrobar Cable and Hydrobar Cable-FR.

With a serial number of the transmitter > 10509426

1.2 Application area

The measuring system can be used for process pressure or level measurement of gases, vapours and liquids

which meet the specific requirements of the safety technology.

1.3 Safety function

The device generates an analogue output signal of 4-20 mA that is proportional to the current pressure.

This has to be controlled by a downstream logical unit (e.g. PLC). For the malfunction detection, the logical

unit has to distinguish between 4-20 mA-signals and the fault current < 3.3 mA or > 20.8 mA. Observe with

the conception of the system, that the technical data of the product-specific as well as Functional Safety

Data Sheet may not be exceeded. Especially the permissible operating condition (permissible temperatures,

etc.) have to be ensured.

Make sure that the entire interconnection of different components fulfills the requirements of the

application. The operator is responsible for correct construction of the overall system.

After installation a validation of the safety function is required.

The installation, maintenance and cleaning of the devices must be performed exclusively by persons

specifically trained and authorized for this purpose as far as they are familiar with the devices!

The operability of the measuring device should be checked via proof test in regularly intervals. For

defining the scope and interval of tests, the following table can be used as a reference. However

each application has its own unique properties and exceptions. Klay Instruments is not an expert in

the customer’s process (technical field) and does not accept liability for consequential damage of

any kind due to use or misuse of the Series 8000 and Hydrobar.

Industry

Application

Frequency of proof test

Twice a year

Yearly

Every two years

Food and Dairy

Fluids

●

Steam and Air

●

Homogenisors

●

Brewery and Beverage

Fluids

●

Steam and Air

●

Homogenisors

●

Pharmaceutical

Fluids

●

Steam and Air

●

Pulp and Paper

Fluids

●

Steam and Air

●

Industry

Application

Frequency of proof test

Twice a year

Yearly

Every two years

Shipbuilding and Marine

Fluids

●

Steam and Air

●

Water and Wasted Water

Fluids

●

Air

●

Chemical and Petrochemical

Fluids

●

Steam, Air and Gasses

●

Oil and Gas

Fluids

●

Steam, Air and Gasses

●

Drilling systems

●

Others (Machinebuilding)

Fluids

●

Steam, Air and Gasses

●

Functional safety manual –Series 8000 and Hydrobar

SM-EN-8000/09-2013/01 Page 3

Modifications on devices and connections void Functional Safety and the warranty!

It is the responsibility of the user to verify whether the chosen version of the device is suitable for

the intended application and the existing environmental conditions. Klay Instruments does not

assume any liability for an incorrect selection and its consequences.

2. Compliance

2.1 Assumptions

The average ambient temperature during the operating time is 20°C - 40 °C (68 °C - 104 °F).

The environmental conditions correspond to an industrial environment.

The lifetime of the components is around 10 to 14 years (IEC 61508-2, 7.4.7.4, remark 3).

2.2 Product identification

Make sure the device has been ordered with SIL-conformity and has been delivered conformably.

The transmitter is clearly marked with a special SIL marking on the enclosure.

2.3 SIL conformity

The SIL conformity is confirmed by the verification documents in the appendix.

Series 8000 and Hydrobar

IEC 61508:2010

Type A

FT0

SIL2

SC2

IEC 61511:2003

Type A

FT1

SIL3

Abbreviations, terms

SIL

Safety Integrity Level

HFT

Hardware Fault Tolerance

SFF

Safe Failure Fraction

PFDAVG

Average Probability of dangerous Failure on Demand

PFH

Probability of a dangerous Failure per Hour

FMEDA

Failure Mode, Effects and Diagnostics Analysis

λsd

Rate for safe detected failure

λsu

Rate for safe undetected failure

λdd

Rate for dangerous detected failure

λdu

Rate for dangerous undetected failure

DCS

Diagnostic Coverage of safe failures; DCS= λsd/(λsd+λsu)

DCD

Diagnostic Coverage of dangerous failures; DCD= λdd/(λdd+λdu)

FIT

Failure In Time (1 FIT = 1 failure/109h)

MTBF

Mean Time Between Failure

MTTF

Mean Time To Failure

MTTR

Mean Time To Repair

Further abbreviations and terms are stated in IEC 61508-4.

2.4 Relevant standards

IEC 61508:2010

Functional safety of electrical/electronic/programmable electronic safety-related systems

IEC 61511-1:2003

Functional safety - safety instrumented systems for the process industry sector - Part 1:

Framework, definitions, system, hardware and software requirements

Functional safety manual –Series 8000 and Hydrobar

SM-EN-8000/09-2013/01 Page 4

3. Safety

3.1 Safety requirements

Failure limit values for a safety function, depending on the SIL class (of IEC 61508-1, 7.6.2)

Safety integrity level

Low demand mode

SIL

PFDavg

≥ 10-5 … < 10-4

≥ 10-4 … < 10-3

≥ 10-3 … < 10-2

≥ 10-2 … < 10-1

Safety integrity of hardware for safety-related subsystems of type A (IEC 61508-2, 7.4.3)

Safe failure fraction

Hardware fault tolerance

SFB

HFT = 0

HFT = 1 (0)

HFT = 2

< 60 %

SIL1

SIL2

SIL3

60 % … < 90 %

SIL2

SIL3

SIL4

90 % … < 99 %

SIL3

SIL4

≥ 99 %

SIL3

SIL4

3.2 Service Proven

According to IEC 61511-1, paragraph 11.4.4, the failure tolerance HFT can be reduced by one for

service-proven subsystems if the following conditions are met:

The hardware of the device is selected on the basis of prior use (see IEC 61511-1 Cl. 11.5.3)

The device allows adjustment of process-related parameters only, for example, measuring

range, upscale or downscale failure direction.

The adjustment of the process-related parameters of the device is protected.

The function has a SIL requirement of less than 4.

SIL

Minimum hardware fault tolerance

(see 11.4.3 and 11.4.4)

Special requirements apply (see IEC 61508)

The user must have experience with this process, and must be in compliance by the requirements of

IEC 61511-1 clause 11.5.3. The operating experience must be recorded in the user’s list of equipment

approved for use in their facilities.

4. Safety-related characteristics

4.1 Basics

The failure rates of the electronics, the mechanical parts of the transmitter as well as the process

fitting are determined by an FMEDA according to IEC 61508. The calculations are based on

component failure rates according to SN 29500. All values refer to an average ambient temperature

during the operating time of 55 °C (104 °F). For a higher average temperature of 60 °C (140 °F), the

failure rates should be multiplied by a factor of 2.5. A similar factor applies if frequent temperature

fluctuations are expected.

Functional safety manual –Series 8000 and Hydrobar

SM-EN-8000/09-2013/01 Page 5

4.2 Safe function

A measurement of absolute and relative pressure or level within the specified safety

accuracy of 0.2 % from full span.

The safety function response time is 50ms.

4.3 Specific characteristics

Failure Rate

Type of rating

Failure in time (FIT)

λsd (safe detected failure)

0.00

λsu (Safe undetected failure)

104.14

λdd (Dangerous detected failure)

0.00

λdu (Dangerous undetected failure)

36.38

Single channel architecture (1oo1D)

SIL

SIL2

HFT

Instrument type

SFF

74 %

PFDavg

TProof = 1 Year

TProof = 2 years

TProof = 5 years

TProof = 10 years

TProof = 15 years

< 0.161 x 10-3

< 0.321 x 10-3

< 0.799 x 10-3

< 0.159 x 10-2

< 0.239 x 10-2

4.4 Time-dependent process of PFDavg

The chronological sequence of PFDavg is nearly linear to the operating time over a period up to 10

years. The above values apply only to the TProof interval after which a recurring function test must

be carried out

4.5 Service life

After 10 to 14 years, the failure rates of the electronic components will increase, whereby the

derived PFD values will deteriorate (IEC 61508-2, 7.4.7.4, note 3).

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