Professional Documents
Culture Documents
Overview
Why is it important to test the Final Control Element of a Safety Instrumented Function (SIF) loop?
Safety Instrumented Systems (SIS), commonly known as Emergency Shutdown (ESD), Emergency Venting (ESV)
or Safety Interlock Systems, are required by standards IEC61508/ISA S84.01 (Replaced by ISA 84.00.012004) to
be tested at a periodic interval based on HAZOP (Hazard Operation Analysis) design to achieve and meet required
Safety Integrity Level (SIL). Traditionally, Safety Instrumented Systems are functionally tested during turnarounds on
a yearly, or every two year basis. Present economies and pressure to maximize production are forcing process
industries to extend shutdown intervals to 3, or in some cases, 5 years. This presents difficulties for the final control
element, which remains untested for a longer time. Unfortunately, Final Control Elements represent a significant
failure contribution in an SIS loop. If offline testing is not possible, then how do we test dormant valves that remain
in one position (by nature of the application) without any mechanical movement?
Using digital valve controllers on Safety Shutdown valves provides local and remote testing capabilities while the plant
is running, along with important diagnostic information on the valve, documentation, and storage of valve test data.
This course shows how using digital valve controllers to perform a partial stroke test to detect dangerous failures can
help to solve problems in testing final control elements in Safety Instrumented Function (SIF) loops.
www.Fisher.com
September 2005
September 2005
Pneumatic Test panels method also uses a pin to engage before partial travel test could be initiated (see figure 3).
September 2005
Because the positioner communicates via HART protocol, the partial stroke test can be initiated from a HART
hand-held communicator, from AMS ValveLink Software, or from a panel-mounted pushbutton hardwired to the
positioner terminals.
AMS ValveLink Software is a PC based software used for the calibration, configuration and diagnostics of FisherR
digital valve controllers (DVC). By using ValveLink Scheduler, a customer can also schedule tests automatically on
a daily, weekly or monthly basis (see figure 4).
September 2005
DVC6000 SIS has the capability to alert the operator if a valve is stuck (see figure 7) by using AMS ValveLink Software.
As the positioner begins the partial stroke, it continually checks the valve travel to see if it is responding properly. This
is important to reduce false trips. Conventional positioners, which do not see travel feedback, may exhaust actuator
pressure trying to move a sticking valve. If the spring force frees the stuck valve after air is depleted, a false trip could
occur. However, the digital valve controller has configurable minimum partial stroke air pressure in microprocessor
memory. Should the valve be in the stuck position, the digital valve controller will abort the test before pressure drops
enough to cause a false trip, and alert the operator that the valve is stuck. This will prevent the valve from slamming
shut if the valve does eventually break loose.
September 2005
In summary, a digital valve controller can provide complete diagnostic health information on the final control element,
including the positioner itself. In addition, the digital valve controller can provide complete documentation of any
emergency event as well as documentation of all testing. Logic Systems DeltaV SIS (see figure 8) can initiate a partial
stroke test and store test results, which could be made available to insurance companies as proof of testing. The
testing and documentation can be completely automated so that expensive operator time is not required.
Figure 8. Logic System, Like DeltaVt, When Used with DVC6000 SIS, Can Initiate Partial Stroke Test
Finally, should an emergency shutdown demand occur during testing, the digital valve controller will override the test,
driving the valve to its safe position.
September 2005
LOGIC SOLVER
SOLENOID VALVE
24 VDC
SEPARATE POWER
SOURCES FOR DIGITAL
VALVE CONTROLLER
AND SOLENOID VALVE
420 MA DC
EXHAUST
TRAVEL FEEDBACK
SUPPLY PRESSURE
Figure 9. SIS Schematic with a Digital Valve Controller in Point to Point Mode
This installation requires an additional pair of wires but it does permit the digital valve controller to continue to
communicate even during emergency demand conditions. This allows the positioner to record valuable trending
information through AMS ValveLink Software during the emergency shutdown.
Figure 10 shows a digital valve controller installed in a multidrop mode. In this installation the logic solver provides
a single 24 volt dc source to provide power for both the solenoid valve and the digital valve controller. This installation
reduces wiring costs in new installations and requires no additional wiring in existing installations. It also saves an I/O
point on the logic system. However, a line conditioner that will add an approximate 2 volt dc line drop and a low
powered solenoid valve are required.
September 2005
LOGIC SOLVER
LOW POWER
SOLENOID VALVE
24 VDC
LINE
CONDITIONER
EXHAUST
TRAVEL FEEDBACK
SUPPLY PRESSURE
Figure 10. SIS Schematic with Digital Valve Controller in Multidrop Mode
Figure 11 shows that the digital valve controller can be mounted in the SIF loop without a solenoid valve. This
arrangement eliminates the cost of the solenoid valve. There are two considerations associated with this
implementation. First, for large volume actuators, where stroking speed is a requirement, the digital valve controller
may not be able to exhaust the air pressure sufficiently fast. Second, this arrangement does not provide a redundant
pneumatic path for exhausting the actuator air pressure.
LOGIC SOLVER
24 VOLT DC POWER
SOURCE
24 VDC
TRAVEL FEEDBACK
LINE
CONDITIONER
SUPPLY PRESSURE
Figure 11. SIS Schematic with Digital Valve Controller without Solenoid Valve
September 2005
Conclusion
A digital valve controller allows testing of the safety shut down valve on-line, while the plant is in operation. It also
provides crucial diagnostics with analyzed test results, enabling planned predictive maintenance rather than
preventive maintenance.
Microprocessor based digital valve controllers store test data in the memory and can generate automatic
documentation for verification by inspection authorities.
Digital valve controllers provide considerable labor savings by automating test scheduling, execution, documentation,
verification, and validation. Partial stroke testing combined with predictive maintenance capability in the digital valve
controller allows the time interval between scheduled shutdowns to be extended, helping the plant to meet higher
availability goals and reducing expensive shutdowns.
Above all, digital valve controllers have features to set minimum partial stroke pressure to avoid spurious trips, and
at the same time, should a demand arise during a test, the digital valve controller will take the valve to safe condition,
without any compromise.
September 2005
Quiz
1. 1)Final Control Element represents significant failure contribution in SIS loop:
a. True
b. False
2. Main problems for testing final control element of SIS loop, by using conventional methods are:
a.
b.
c.
d.
e.
3. By introducing Partial Stroke test and increasing test frequency a digital valve controller:
a.
b.
c.
d.
Can test valves more frequently to check mechanical movement & diagnostics
Can improve SIL Level of existing loop
Can extend turnaround period
All of above
5. Digital valve controllers (Microprocessor based) for Safety Instrumented Function (SIF) loops
a.
b.
c.
d.
Fisher is a mark owned by Fisher Controls International LLC, a member of the Emerson Process Management business division of Emerson
Electric Co. Emerson and the Emerson logo are trademarks and service marks of Emerson Electric Co. HART is a mark owned by the HART
Communication Foundation. All other marks are the property of their respective owners.
The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are
not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability.
We reserve the right to modify or improve the designs or specifications of such products at any time without notice.
Neither Emerson, Emerson Process Management, Fisher, nor any of their affiliated entities assumes responsibility for the selection, use and
maintenance of any product. Responsibility for the selection, use and maintenance of any product remains with the purchaser and end-user.
Printed in USA