Samson 3241 Manual
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Samson 3241 Manual

Competence in functional safety
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MANUAL
Competence in Functional Safety
Functional safety of globe
valves, rotary plug valves, ball valves and butterfly valves
SMART IN FLOW CONTROL.

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Summary of Contents for Samson 3241

  • Page 1 MANUAL Competence in Functional Safety Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves SMART IN FLOW CONTROL.
  • Page 2 SAMSON AIR TORQUE · CERA SYSTEM · KT-ELEKTRONIK · LEUSCH PFEIFFER · RINGO · SAMSOMATIC · STARLINE · VETEC Founded in 1907 , SAMSON has since become a worldwide leader in the manufacture of expertly engineered control valves. SAMSON has over 50 subsidiaries, amongst them noted manufacturers of special valves.

  • Page 3: Table Of Contents

    Competence in Functional Safety Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves Table of contents 1 Scope ................................4 2 Validity of this manual ............................4 3 Intended use of this manual ..........................5 4 General aspects of functional safety........................6 4.1 Standards, terms and abbreviations ......................6 4.2 Determining the safety integrity level ......................8 4.3 Hardware fault tolerance ..........................9...

  • Page 4: Scope

    Valves and the associated actuators are used to isolate pipelines in safety-instrumented systems. Alternatively, they can also be used for pressure relief, i.e. by completely opening valves. Validity of this manual This manual applies to control valves manufactured by the following companies within SAMSON: SAMSON AG „...

  • Page 5: Intended Use Of This Manual

    Competence in Functional Safety Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves Intended use of this manual This manual is intended to assist planners and operators during the integration of control valves into a safety loop as part of the safety function and to enable them to safely operate control valves.

  • Page 6: General Aspects Of Functional Safety

    Competence in Functional Safety Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves General aspects of functional safety 4.1 Standards, terms and abbreviations Abbreviation Designation Description Safety Integrity Level One of four discrete levels for specifying the safety integrity requirements of the safety functions to be allocated to the E/E/PE safety-related systems, where SIL 4 has the highest level of safety integrity and SIL 1 has the lowest.
  • Page 7 Competence in Functional Safety Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves Abbreviation Designation Description MooN Voting “M out of N“ (e. g. 2oo3) Classification and description of the safety-related system regarding redun- dancy and the selection procedure used. • “N“...

  • Page 8: Determining The Safety Integrity Level

    Competence in Functional Safety Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves 4.2 Determining the safety integrity level The achievable safety integrity level (SIL) is determined by the following safety-related data: Average probability of failure on demand (PFD „...

  • Page 9: Hardware Fault Tolerance

    Competence in Functional Safety Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves 4.3 Hardware fault tolerance In the process industry, the achievable SIL classes for sensors, final elements and non-programmable logic modules, such as isolating amplifiers and relays, are restricted in accordance with IEC 61511 as shown in the following table. Safety integrity level (SIL) Minimum required hardware failure tolerance (HFT) Special requirements (refer to IEC 61508)

  • Page 10: Intended Use Of Control Valves In Safety-Instrumented Systems

    Competence in Functional Safety Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves Intended use of control valves in Responsibility safety-instrumented systems The reliability of mechanical components is significantly affected by the operating condi- tions and, as a result, by systematic failures. This needs to be taken into account when selecting and sizing devices.
  • Page 11 Competence in Functional Safety Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves Responsibility The joint use of a control valve within the safety loop by a control loop of a basic „ „ process control system makes it possible to increase the diagnostic coverage of the safety-instrumented system.

  • Page 12: General Control Valve Requirements

    Note: A larger nominal size is needed when the connection length exceeds 2 m. „ Example: Connecting pipe cross-sections required for SAMSOMATIC Type 3963 Solenoid Valve SAMSON uses calculation methods to predict the transit time and to size the pneumatic Manufacturer hook-up. SAMSON can support users in selecting devices on request.

  • Page 13: Globe Valve Requirements

    Competence in Functional Safety Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves 5.2 Globe valve requirements Responsibility If there is a risk of solids contained in the process medium causing blockage, Operator „ „ a strainer must be fitted. Safety equipment with fail-open action must not be operated with strainers.
  • Page 14 Competence in Functional Safety Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves Responsibility It is essential to check the actuator forces to ensure that the valve can overcome „ „ the process pressures to reach its fail-safe position. This can be checked by the manufacturer if requested.

  • Page 15: Ball Valve Requirements

    Competence in Functional Safety Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves 5.3 Ball valve requirements Responsibility Note for ball valves that higher initial breakaway torques arise as the differential pressure Manufacturer „ „ of the process medium rises, requiring higher actuator torques. Differential pressure ∆p (bar) (Nm) (Nm)

  • Page 16: Butterfly Valve Requirements

    Competence in Functional Safety Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves 5.4 Butterfly valve requirements Responsibility On sizing actuators for butterfly valves, note that the actuator must provide suf- „ „ ficient torque to overcome the breakaway torque and closing torque in closed position as well as the dynamic torque in open position.
  • Page 17 Competence in Functional Safety Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves Responsibility Media, especially degreasing, swelling and fibrous media, may affect the torque. Operator „ „ The operating conditions, e.g. switching interval and the medium temperature, have „...

  • Page 18: Rotary Plug Valve Requirements

    Competence in Functional Safety Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves 5.5 Rotary plug valve requirements Responsibility On sizing actuators, note that the actuator must provide sufficient torque to over- „ „ come the closing torque in closed position as well as the dynamic torque in open position.

  • Page 19: Installation, Piping And Wiring

    Competence in Functional Safety Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves Installation, piping and wiring Responsibility 6.1 Mechanical and pneumatic installation During mechanical and pneumatic installation, the mounting and operating instructions Operator „ „ of the corresponding device must be observed.

  • Page 20: Electrical Installation

    Competence in Functional Safety Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves 6.2 Electrical installation Responsibility Only cables with the prescribed outer diameter of the cable glands may be used. Operator „ „ For EExi circuits the electrical cable data must comply with the data taken as „...
  • Page 21 Competence in Functional Safety Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves Responsibility To ensure the control valve functions properly, the pipeline must be designed to be „ „ straight and without any manifolds or disturbances for a distance of at least six times the pipe size (DN) upstream and downstream of the valve.

  • Page 22: Applicable Device Documentation

    Each control valve has a data sheet, mounting and operating instructions as well as a certificate of conformity in accordance with the European Pressure Equipment Directive (PED) 2014/68/EU and, if applicable, an explosion protection certificate. These documents are available in various languages on the Internet at www.samson.de, www.vetec.de, www.pfeiffer-armaturen.com and www.leusch.de.
  • Page 23 Competence in Functional Safety Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves...
  • Page 24 Competence in Functional Safety Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves...
  • Page 25 Competence in Functional Safety Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves...
  • Page 26 Competence in Functional Safety Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves...
  • Page 27 Competence in Functional Safety Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves...
  • Page 28 Competence in Functional Safety Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves...
  • Page 29 Competence in Functional Safety Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves...

  • Page 30: Appendix 2 − Example Of A Checklist For A Final Element

    Competence in Functional Safety Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves Competence in Functional Safety Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves Appendix 2 − Example of a checklist for a final element Appendix 2 −...

  • Page 31: Serial Number

    Competence in Functional Safety Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves Competence in Functional Safety Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves Checklist for testing safety equipment Owner Created/Revised by: Operation: Plant:...
  • Page 32 MANUAL Competence in Functional Safety Production sites Subsidiaries SAMSON AKTIENGESELLSCHAFT Weismuellerstrasse 3 · 60314 Frankfurt am Main; Germany Phone: +49 69 4009-0 · Fax: +49 69 4009-1507 E-mail: samson@samson.de · Internet: www.samson.de SMART IN FLOW CONTROL.

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