Magnetrol Jupiter JM4 Guía del usuario

SIL Safety Manual

Model JM4

Software v1.x

Magnetostrictive Level

Transmitter

is manual complements and is intended to be used

with the Orion Instruments® Jupiter® Model JM4

Magnetostrictive Level Transmitter Installation and

Operating Manual (Bulletin ORI-650).

2ORI-652 Jupiter®Model JM4 Magnetostrictive Transmitter – SIL Safety Manual

1.0 Introduction

1.1 Product Description ......................... 3

1.2 eory of Operation ......................... 3

1.3 Determining Safety Integrity Level (SIL) ......... 3

2.0 Level Measuring System

2.1 Miscellaneous Electrical Considerations .......... 4

2.1.1 Pollution Degree 2 .................... 4

2.1.2 Over-voltage ........................ 4

3.0 Mean Time To Restoration (MTTR)

4.0 Supplementary Documentation

5.0 General Instructions

5.1 Systematic Limitations ....................... 5

5.1.1 Application ......................... 5

5.1.2 Environmental ....................... 6

5.1.2.1 Storage .......................... 6

5.2 Installation ................................ 6

5.3 Skill Level of Personnel ....................... 6

5.4 Necessary Tools............................. 6

5.5 Conguration .............................. 6

5.5.1 General ............................ 6

5.5.2 Conguration ....................... 7

5.5.3 Write Protecting/Locking................ 7

5.6 Site Acceptance Testing....................... 7

5.7 Recording Results ........................... 7

5.8 Maintenance............................... 7

5.8.1 Diagnostics ......................... 7

5.8.2 Troubleshooting ...................... 8

6.0 Recurrent Function Tests

6.1 Proof Testing............................... 8

6.1.1 Introduction ........................ 8

6.1.2 Interval ............................ 8

6.1.3 Recording Results .................... 8

6.1.4 Suggested Proof Test ................... 8

7.0 Appendices

7.1 SIL Declaration of Conformity................ 11

7.2 FMEDA Report: exida Management Summary ... 11

7.3 Specic Model JM4 Values ................... 13

7.4 PFD Graph............................... 13

7.5 Report: Lifetime of Critical Components ........ 14

References ...................................... 15

Table of Contents

Jupiter® Model JM4 Magnetostrictive Transmitter

SIL Safety Manual

ORI-652 Jupiter®Model JM4 Magnetostrictive Transmitter – SIL Safety Manual 3

1.0 Introduction

1.1 Product Description

e JUPITER Model JM4 magnetostrictive level transmitter is a

loop-powered 24 VDC level transmitter based on magnetostric-

tive technology.

NOTE: For Safety Instrumented Systems usage, it is assumed that

the 4-20 mA output is used as the primary safety variable.

e analog output for the Model JM4 meets the NAMUR

NE 43 standard (3.8 mA to 20.5 mA usable). e transmitter

contains self-diagnostics and is programmed to drive the output

to a user-selected failure state, either low or high, upon internal

detection of a diagnostic indicator. e device can be equipped

with or without a graphic liquid crystal display (LCD).

Table 1 indicates the version of the JUPITER Mode JM4

transmitter suitable for SIL 2 applications based on the hardware

assessment.

1.2 Theory of Operation

Magnetostrictive level sensors are based on “time-of-ight”

technology.

Permanent magnets contained within a oat device track the

process liquid as it changes level. e JUPITER probe is xed

within close proximity to this magnetic eld. A short current

pulse is then applied to a specially designed wire alloy contained

within the probe. e interaction of the current pulse and

magnetic eld causes distortion in a small section of the wire

alloy. is in turn creates a vibratory disturbance which begins

to travel through the wire at a very constant rate of speed. e

disturbance is later detected via a sensing device at the top of

the probe and sent to the electronics unit where it is ltered and

amplied.

Extremely accurate level measurement can thus be obtained

precisely measuring the elapsed time between the current pulse

(start), and the returned pulse (stop). e JUPITER electronics

module processes these signals, and then performs various math-

ematical operations in order to provide the user with an analog

and/or digital representation of the liquid level.

1.3 Determining Safety Integrity Level (SIL)

e JUPITER Model JM4 is classied as a Type B device

according to IEC61508.

Tables 2 & 3 dene the criteria for the achievable SIL against the

target mode of operation in Demand Mode Operation.

• Table 2 shows the relationship between the Safety Integrity

Level (SIL) and the Probability of Failure on Demand Average

(PFDavg).

Table 1

JUPITER JM4 Model Number

Table 2

SIL vs. PFDavg

Safety

Integrity Level

(SIL)

Target Average

probability of failure on

demand (PFDavg)

4≥ 10-5 to < 10-4

3≥ 10-4 to < 10-3

2≥ 10-3 to < 10-2

1≥ 10-2 to < 10-1

Table 3

Minimum hardware fault tolerance

Type B sensors, nal elements and non-PE logic solvers

SFF

Hardware Fault

Tolerance (HFT)

0 1 2

None: < 60% Not

Allowed SIL 1 SIL 2

Low: 60% to < 90% SIL1 SIL 2 SIL 3

Medium: 90% to <99% SIL 2 SIL3

High: ≥99% SIL 3

Model:JM4-511X-XXX (HART Transmitter)

2YX-XXXX-XXX-XX-XXX (Probe)

4ORI-652 Jupiter®Model JM4 Magnetostrictive Transmitter – SIL Safety Manual

• Table 3 is used to determine the achievable SIL as a function of

the Hardware Fault Tolerance (HFT) and the Safe Failure Frac-

tion (SFF) for the complete safety function (Type B — complex

components as per IEC 61508 Part 2) of which the level transmit-

ter is one component.

2.0 Level Measuring System

e diagram at left shows the structure of a typical measuring

system incorporating the JUPITER Model JM4 transmitter.

is SIL-rated device is only available with an analog signal

(4–20mA) with HART communications, and the measurement

signal used by the logic solver must be the analog 4–20mA

signal proportional to the level.

• For fault monitoring, the logic unit must recognize both high

alarms (≥ 21.5 mA) and low alarms (≤ 3.6 mA).

• If the logic solver loop uses intrinsic safety barriers, caution must

be taken to ensure the loop continues to operate properly under

the low alarm condition.

• e only unsafe mode is when the unit is reading an incorrect

level within the 4–20 mA range (> ±2% deviation).

• MAGNETROL denes a safe failure as one in which the

4–20mA current is driven out of range (i.e., less than 3.8 mA

or greater than 21.5 mA).

2.1 Miscellaneous Electrical Considerations

Following are miscellaneous electrical issues to be considered in a

safety system.

2.1.1 Pollution Degree 2

e JUPITER Model JM4 transmitter is designed for use in a

Category II, Pollution Degree 2 installation, which is dened

by the non-conductive pollution of the sort where occasionally

a temporary conductivity caused by the condensation must be

expected.

is is the usual pollution degree used for equipment being

evaluated to IEC/EN 61010.

2.1.2 Over-voltage

e JUPITER Model JM4 transmitter has, as standard,

over-voltage protection per CE requirements. When considering

Hi-pot, Fast Transients, and Surge, this protection is to 1000

volts (1KV). erefore, there should be no unsafe failure modes

up to 1 KV.

PACTwareTM with

Jupiter® x.x DTM

HART Modem

Actuator

Jupiter®Model JM4

Logic

Unit

ORI-652 Jupiter®Model JM4 Magnetostrictive Transmitter – SIL Safety Manual 5

Overvoltage Category II is a local level, covering appliances, por-

table equipment, etc., with smaller, transient overvoltages than

those characteristic of Overvoltage Category III. is category

applies from the wall plug to the power-supply isolation barrier

(transformer).

As the typical plant environment is Overvoltage Category II,

most equipment evaluated to the requirements of IEC/EN

61010 are considered to belong in that classication.

3.0 Mean Time To Restoration (MTTR)

SIL determinations are based on a number of factors including

the Mean Time To Restoration (MTTR). e analysis for the

JUPITER Model JM4 is based on a MTTR of 24 hours.

4.0 Supplementary Documentation

• e JUPITER Model JM4 Installation and Operating Manual

ORI-650 must be available to ensure proper installation of the

transmitter.

• One of the following Electronic Device Description Files is also

required if HART is used:

• Manufacturer Code 56 (hex)

• Model JM4 Device ID 56DF (hex), device revision 1, DD

revision 1.

• For device installations in a classied area, the relevant safety

instructions and electrical codes must be followed

5.0 General Instructions

5.1 Systematic Limitations

e following instructions must be observed to avoid systematic

failures.

5.1.1 Application

Choosing the proper accessories and options for the JUPITER

Model JM4 transmitter is an important decision in the

application process. High temperature and cryogenic probes

are available for extreme temperature situations. Vibration

absorption kits are also available for high vibration applications.

As the probe conguration establishes fundamental performance

characteristics, the probe for use with the JUPITER Model JM4

must be carefully selected. Appropriate selection of Probe design

and materials as well as oat characteristics and material will

assure reliable operation. Refer to Installation and Operating

Manual ORI-650 for more information on selecting the proper

options for each specic application.

6ORI-652 Jupiter®Model JM4 Magnetostrictive Transmitter – SIL Safety Manual

5.1.2 Environmental

Refer to Installation and Operating Manual ORI-650 for envi-

ronmental limitations.

5.1.2.1 Storage

e device should be stored in its original shipping box and not

be subjected to temperatures outside the storage temperature

range of -50 to +185 °F (-46 to +85 °C).

5.2 Installation

Refer to the Model JM4 Installation and Operating Manual

ORI-650 for complete installation instructions.

I/O Manual ORI-650:

• Contains information on the use, changing and resetting of the

password-protection function.

• Provides menu selection items for conguration of the transmit-

ter as a level sensing device.

• Oers conguration recommendations.

NOTE: This SIL evaluation has assumed that the customer will be

able to acknowledge an over- or undercurrent condition via

the Logic Solver.

5.3 Skill Level of Personnel

Personnel following the procedures of this safety manual should

have technical expertise equal to or greater than that of a quali-

ed Instrument Technician.

5.4 Necessary Tools

Following are the necessary tools needed to carry out the pre-

scribed procedures:

• Open-wrenches or adjustable wrench to t the process connec-

tion size and type.

• Flat-blade screwdriver

• Digital multimeter or digital volt/ammeter

• 24 VDC power supply, 23 mA minimum

• Hex key 2.5 mm to lock transmitter in place on the probe and

to lock transmitter rotational position

5.5 Conguration

5.5.1 General

e JUPITER Model JM4 transmitter can be congured via the

local display, a HART compatible handheld terminal, or a per-

sonal computer using the PACTware™ and the associated DTM.

ORI-652 Jupiter®Model JM4 Magnetostrictive Transmitter – SIL Safety Manual 7

5.5.2 Conguration

Ensure the parameters have been properly congured for the

application and probe. Special consideration should be given to

the following conguration parameters:

FAULT: DO NOT choose HOLD for this parameter as a Fault

will not be annunciated on the current loop.

BLOCKING DISTANCE: is value MUST be zero for SIL

applications. Consult factory prior to making any changes.

LOOP CONTROL MODE: Ensure this is set to ENABLED.

PASSWORD: Must be changed to a specic value other than

Zero.

5.5.3 Write Protecting/Locking

e Model JM4 transmitter is password protected with a numer-

ical password between 0 and 99,999.

NOTE: Default Password = 0 = Password disabled

Refer to the Model JM4 Installation and Operating Manual

Bulletin ORI-650 for additional information on password pro-

tection.

It is required that, after conguration of the system is complete,

a password is utilized to prevent inadvertent changes to the

device.

5.6 Site Acceptance Testing

To ensure proper operation after installation and conguration,

a site acceptance test should be completed. is procedure is

identical to the Proof Test Procedure described in Section 6.1.4.

5.7 Recording Results

Results of Site Acceptance Testing must be recorded for future

reference.

5.8 Maintenance

5.8.1 Diagnostics

Internal diagnostic testing within the Model JM4 transmitter

occurs approximately ve times per second (1 every 100 ms). A

message will appear and the output current will be driven to 3.6

or 22 mA (customer dependent) upon detection of a fault.

8ORI-652 Jupiter®Model JM4 Magnetostrictive Transmitter – SIL Safety Manual

5.8.2 Troubleshooting

Report all failures to the MAGNETROL technical support

department.

Refer to the Model JM4 Installation and Operating Manual

ORI-650 for troubleshooting device errors.

• e SIL Proof Test provides a reliable indication when mainte-

nance is required.

• Firmware can be upgraded only by factory personnel.

6.0 Recurrent Function Tests

6.1 Proof Testing

6.1.1 Introduction

Following is the procedure utilized to detect Dangerous Unde-

tected (DU) failures. is procedure will detect approximately

83% of the Dangerous Undetected (DU) failures in the Jupiter

Model JM4-511X-XXX.

6.1.2 Interval

To maintain the appropriate Safety Integrity Level of a Safety

Instrumented System, it is imperative that the entire system be

tested at regular time intervals (shown as TI in the appropriate

standards). e suitable SIL for the Model JM4 transmitter is

based on the assumption that the end user will carry out this test

and inspection at least once per year.

NOTE: It is the responsibility of the owner/operator to select the type

of inspection and the time period for these tests

6.1.3 Recording Results

Results of the Proof test should be recorded for future reference.

6.1.4 Suggested Proof Test

e suggested proof test described on pages 9–10 will detect

83% of the possible DU failures that remain after taking into

account automatic diagnostics. e suggested proof test in com-

bination with automatic diagnostics will detect 98% of possible

DU failures in Model JM4-511x-xxxx.

ORI-652 Jupiter®Model JM4 Magnetostrictive Transmitter – SIL Safety Manual 9

Step Action

1Bypass the PLC or take other action to avoid a false trip.

Remove power from the Unit. (This clears any potential soft RAM errors.) Inspect the Unit in

detail outside and inside for physical damage or evidence of environmental or process leaks.

a.) Inspect the exterior of the unit housing. If there is any evidence of physical damage that

may impact the integrity of the housing and the environmental protection, the unit should

be repaired or replaced.

b.) Inspect the interior of the Unit. Any evidence of moisture, from process or environment, is

an indication of housing damage, and the unit should be repaired or replaced.

Restore power to the Unit. Use the Unit’s “DIAGNOSTICS” menu to observe “Present Status”

and to review “EVENT HISTORY”. Up to 10 events are stored. The events will be date and

time stamped if the internal clock is set and running. It is suggested that the internal clock be

set at the time of commissioning of the unit. If the clock is set at the time of the proof test event

times are calculated.

a.) Observe the “Present Status”. “Present Status” should be “OK”.

b.) Review the “EVENT HISTORY”.

i.) Messages in the “EVENT HISTORY” must be investigated and understood.

ii.) Corrective actions should be taken for critical messages that indicate performance may

be affected.

Use the Unit’s “DIAGNOSTICS” menu to perform a loop current test. Choose the menu “DIAG-

NOSTIC/ADVANCE DIAGNOSTICS/TRANSMITTER TESTS/Analog Output Test” to change the

output loop current and conrm the actual loop current matches the value chosen.

a.) Send a HART command to the transmitter (or use the local user interface) to go to high

alarm current output, 22mA, and verify that the analog current reaches that value.

i.) This step tests for compliance voltage problems such as low supply voltage or increased

wiring resistance.

ii.) This also tests for current loop control circuitry and adjustment problems.

b.) Send a HART command to the transmitter (or use the local user interface) to go to low

alarm current output, 3.6mA, and verify that the analog current reaches that value.

i.) This step tests for high quiescent current and supply voltage problems.

ii.) This also tests for current loop control circuitry and adjustment problems.

c.) Exit the “Analog Output Test” and conrm that the output returns to original state, with the

proper loop current as indicated and controlled by the unit.

10 ORI-652 Jupiter®Model JM4 Magnetostrictive Transmitter – SIL Safety Manual

Step Action

Use the “DIAGNOSTICS” menu to observe the present Echo Curve and document typical per-

formance values. Conrm that the ECHO Waveform is normal. The ECHO curve is dependent

on the probe used and the level of the process on the probe. It is recommended that a typical

ECHO curve be saved at commissioning. Comparison of the ECHO curve at proof test to one

stored at the time of commissioning gives additional condence of the normal operation of the

unit. Use of digital communications (HART enhanced DD or DTM) is necessary for comparison

of echo curves. For a dual oat unit repeat the steps below for the second oat and document

“Upr Echo Strength” and “Ifc Echo Strength” as well as “Upr Noise / Threshold” and “Ifc Noise /

Threshold”.

a.) Move the process level so the oat is located at a distance of approximately 33% of probe

length from the connector end of the probe.

b.) Choose the menu “DIAGNOSTICS/ECHO CURVES/ View Echo Curve”.

i.) Observe the present Echo Curve, identify the characteristic portions of the waveform

related to the top of the probe and oat location.

ii.) Conrm signal from the oat appears normal and is located as expected.

iii.) Verify the baseline of the waveform is normal and does not have evidence of excessive

noise.

iv.) If possible, compare to Echo curve from commissioning to assure that performance has

not changed signicantly.

c.) Choose the menu “DIAGNOSTICS/ADVANCED DIAGNOSTICS/ INTERNAL VALUES”.

i.) Observe and record:

Upper Interface

1. Echo Strength __________ ___________

2. Lvl Noise / Threshold __________ ___________

ii.) Conrm that these values match the values observed at commissioning of the unit and/

or at previous Proof Tests.

1. Echo Strength change is less than ±15.

2. Lvl Noise / Threshold is less than ±15.

Perform a two point calibration check of the transmitter by applying level to two points on the

probe and compare the transmitter display reading and the current level value to a know refer-

ence measurement.

7If the calibration is correct the proof test is complete. Proceed to step 9.

If the calibration is incorrect, remove the transmitter and probe from the process. Inspect the

probe for buildup or clogging. Clean the probe if necessary. Perform a bench calibration check

by moving the oat to two points on the probe. Measure the level from the bottom of the probe

to the points and compare to the transmitter display and current level readings.

a.) If calibration is off by more than 1%, call the factory for assistance.

b.) If calibration is correct, the proof test is complete. Re-install the probe and transmitter and

proceed to step 9.

9Restore the loop to full operation.

10 Remove the bypass from the safety PLC or otherwise restore normal operation.

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