Flowserve Limitorque MX Safety Manual
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Flowserve Limitorque MX Safety Manual

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Limitorque MX Electronic Actuator
FCD LMENIM2350-02 A4 – 05/16
Experience In Motion
FLOWSERVE LIMITORQUE PROPRIETARY INFORMATION
Flowserve's proprietary rights are included in the information disclosed herein. Recipient, by accepting this document, agrees that neither this document nor the information disclosed herein nor any part thereof shall be reproduced or transferred to other
documents or used or disclosed to others for manufacturing or for any other purpose except as specifically authorized in writing by Flowserve.
SAFETY MANUAL
Maintenance
Installation
Operation

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Summary of Contents for Flowserve Limitorque MX

  • Page 1 FLOWSERVE LIMITORQUE PROPRIETARY INFORMATION Flowserve’s proprietary rights are included in the information disclosed herein. Recipient, by accepting this document, agrees that neither this document nor the information disclosed herein nor any part thereof shall be reproduced or transferred to other...

  • Page 2: Table Of Contents

    Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 Contents Scope 1.1 System Overview Safety Integrity Level [SIL] 2.1 Failure Rates/Failure Modes λ 2.1.1 Safe, but Detected ( λ 2.1.2 Safe, but Undetected ( λ 2.1.3 Dangerous, but Detected ( λ...
  • Page 3 Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 7.3 Basic PST Configuration Options and Operation 7.3.1 Remote Input Option for Digital Input 1 (Terminal 34, or D2) 7.3.2 Monitor Relay Actions During PST 7.3.3 Digital Output (Relay Contact) Configuration Options for PST 7.3.4 PST Status Indicators...
  • Page 4 Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 Tables Table 1.1 – Available Functional Options Table 2.1 – SIL vs PFD Table 6.1 – PFD for MXa Actuator without PST Table 6.2 – PFD for MXa Actuator with Monthly PST Table 7.1 –...

  • Page 5: Scope

    This document is a Safety Manual for the Basic Limitorque™ MXa electronic actuator system with Standard Controls Package as developed for the Limitorque branded actuators that are manufactured by Flowserve Corporation. Optional printed circuit boards may be included with the basic actuator as shown in the following table. However, while the inclusion of those options will not result in a change to the Safety Integrity Level [SIL], their use will result in a slight reduction in values for some of the safety metrics as shown in sections 6 and 8.

  • Page 6: System Overview

    For further details, refer to Instruction, Operation & Maintenance [IOM] manual for Limitorque MX Electronic Actuator, LMENIM2306. The latest version may be found on the Flowserve web site at www.flowserve.com.

  • Page 7: Safety Integrity Level [Sil]

    Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 Safety Integrity Level (SIL) The international standard IEC 61508 defines four Safety Integrity Levels (SIL) from SIL 1 to SIL 4. Each level provides an expectation for the probability of a failure on demand for a given safety function. Higher SIL values indicate higher integrity against random failure probability that a safety function will perform when required (see Table 1 for relative comparisons) and higher integrity against systemic failures.

  • Page 8: Proof Test Period (Tpt)

    Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 Proof Test Period (Tpt) Full stroke test at least once per year ==> 8760 hr Based upon the extent of the proof test, failures undetected during normal operation or during PST may be uncovered during full proof test.

  • Page 9: Safety Requirements

    Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 Safety Requirements 3.1 Monitor Relay Annunciation Any operating mode or self-detected system failure that could prevent the actuator from performing its Safety Instrumented Function on demand from the Safety Instrumented System shall cause the actuator’s monitor relay to de-energize, thus providing indication to the user via the alarm contacts on the monitor relay that the actuator may need to be serviced.

  • Page 10: Proof Test Interval

    Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 3.6 Proof Test Interval User should perform a full stroke proof test sequence at least once per year during the mission life of the actuator. 3.7 Basic Safety Configuration Requirements Actuator should be configured and wired for emergency operation and partial stroke testing as shown in section 9.4 of this document.

  • Page 11: Design For Safety

    Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 Design for Safety Figure 4.1 - Safety Block Diagram - Basic ESD and PST Monitor Relay Monitor Relay Case A‐B‐C‐D Meaning Action De‐energises? Case A‐B‐C‐D Meaning Action De‐energises? 0001 Invalid STOP 0001 Invalid...

  • Page 12: Limigard

    Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 4.1 LimiGard™ LimiGard™ is at the heart of the design for safety that is integral to every Limitorque MXa and QX commercial and/or SIL-rated electric actuator. LimiGard is a patented digital command and monitoring system that employs coded signals throughout and automati- cally monitors the health of each signal to ensure that no component failure in the signal path can cause the actuator to move unexpectedly.

  • Page 13: Safety Critical User Wiring

    Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 4.2.2 Safety Critical User Wiring The LimiGard concept can be extended to user wiring as shown in Safety Block Diagram - Enhanced User Wiring (Figure 4.2 below) and configuring the actuator in accordance with subsection 10.5, Custom Input Mode - Momentary ESD/PSESD (Optional).

  • Page 14: Limitorque Mxa Safety Functions

    Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 Limitorque MXa Safety Functions 5.1 Emergency Shutdown Open (ESD-Open) A remote, external ESD signal may be applied to the actuator to move the valve to the OPEN position through predeter- mined, user-configured shutdown position, overriding existing control signals.

  • Page 15: Fail No-Action (Stay Put) Operation

    Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 5.6 Fail No-Action (Stay Put) Operation The system is designed so that any single-point failure in the microprocessor-controlled signal lines will automatically halt or prevent motor motion. We refer to this philosophy as “Fail No-Action.”...

  • Page 16: Mxa Safety

    Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 MXa Safety 6.1 Basic board set Table 6.1 - PFD for MXa Actuator without PST Proof Test Interval Mission Time 1 year 3 years 5 years 10 yr 5.24 E-3 1.28 E-2 2.18 E-2...

  • Page 17: Pfdavg For Mxa Acutator With Monthly Pst

    Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 In other words, using an MXa in an SIL-2 SIF will absorb 52.4% of the available bandwidth for SIL-2. In order to maintain a SIL-2 capability for the entire SIF, the total of the PFDavg values for all of the components that comprise the SIF must sum to no more than 0.01.

  • Page 18: Partial Stroke Testing [Pst]

    Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 Partial Stroke Testing (PST) To ensure that the actuator remains ready to perform its safety function and to detect those faults that the actuator cannot discover by its automated Built-In Self-Test [BIST], it is strongly recommend that the user should perform periodic Partial Stroke Testing [PST].

  • Page 19: Monitor Relay Behavior When Configured As Enhanced Pst

    Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 While PST signals are in their normal state, the user may command an ESD action by momentarily asserting the ESD signal. The actuator will move the valve to its configured ESD position and keep it there until it receives an ESD release command.

  • Page 20: Digital Output (Relay Contact) Configuration Options For Pst

    Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 7.3.3 Digital Output (Relay Contact) Configuration Options for PST Status (S) alarm contacts configuration options include the following. 7.3.3.1 PST Active This function shall be set when PST STATUS is active. This function shall be reset when PST STATUS is configured, passed or failed.

  • Page 21: Actions Upon Successful Completion Of The Pst Stroke

    Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 7.3.8 Actions Upon Successful Completion of the PST Stroke • PST status shall be set to Passed. • LCD indicates “STATUS OK.” • Any status relay that is configured as PST Completed Successfully shall assume its configured state.

  • Page 22: Actions During Power-Down Cycle During Pst Event

    Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 • Event: Actuator moved out of remote mode. • Actions: Actuator stops motion. LCD reports “STATUS OK.” Monitor relay de-energizes. PST status indicators set to either PST failed to reach target position in allotted time or PST failed to return to starting position in allotted time as appropriate.

  • Page 23: Safety Instrumental System (Sis) Assessment

    Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 Safety Instrumented System (SIS) Assessment The actuator is a type B product that is fit for function in SIS that may require Safety Integrity Levels 2 or 3. All Safety Instrumented Functions may be employed for SIL2 and SIL3 SIS (see section 5 Limitorque MXa Safety Instrumented Functions [SIF]).

  • Page 24: Commissioning

    Flowserve strongly recommends remote communication wiring be routed separately from line power wiring. Specifically, instrumentation wiring, including communication, analog and discrete signal signals, should be routed in conduits or raceways that are separate from power wiring. Flowserve cannot guarantee the reliability of instrumentation signaling if this recommendation is not implemented.

  • Page 25: Pst And Pst/Esd Configuration

    Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 9.4 PST and PST/ESD Configuration 9.4.1 Basic Configuration The basic PST/ESD configuration may be configured such that separate signals may be dedicated individually to PST and ESD functions. However, the enhanced PST and PST/ESD configuration employs redundant but logically opposite signals to enable PST and to release an ESD action.
  • Page 26 Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 ENTER Display: PASSWORD? Toggle the black OPEN-CLOSE knob: → OPEN (YES) → Release (Following screens assume default password = 100) [0] 0 0 Display: DIGIT 1 - OK? Toggle the black OPEN-CLOSE knob: → CLOSE (NO) → Release...

  • Page 27: Set Up Basic Esd And Pst

    Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 9.4.4 Set Up Basic ESD and PST NOTE: For Enhanced ESD & PST, skip to step 9.4.5 Figure 9.1 - Accessing the SIF Configuration Dialog Figure 9.2 - Basic SIF & PST Configuration Dialog flowserve.com...

  • Page 28: Set Up Enhanced Esd And Pst

    Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 9.4.5 Set Up Enhanced ESD and PST NOTE: Enhanced ESD and PST is a factory-enabled option that should be purchased with the actuator. It may be added to in-service actuators but service and acquisition fees will be applied.

  • Page 29: Emergency Shutdown (Esd)

    Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 Emergency Shutdown (ESD) ESD signals may be applied to the actuator to override any existing command signal and send the valve to its pre- selected shutdown position, providing the actuator is in the remote mode.

  • Page 30: Configurable Esd Overrides

    • Motor thermal protection. WARNING: Disabling the motor over-temperature, valve jammed or over-torque protection features are permitted, but by doing so, the user chooses to void the Flowserve warranty and all third-party certifications, including Factory Mutual, CSA, IECex and ATEX.

  • Page 31: Esd (Emergency Shutdown) Overrides

    Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 ESD (Emergency Shutdown) Overrides An external contact may be used to place the actuator in emergency shutdown mode. An ESD contact may be connected to the actuator to override existing command signals and send the valve to a predetermined position.

  • Page 32: Local Command Override

    Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 11.1.2 Local Command Override Default = LOCAL>ESD Select “NO” to choose: “ESD>LOCAL” – ESD overrides local command to operate actuator “LOCAL>ESD” – Local command to operate actuator overrides ESD 11.1.3 Stop Override Default = STOP>ESD...

  • Page 33: Figure 11.2 - Configuring Sif (Esd)

    Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 Figure 11.2 - Configuring SIF (ESD) See Note 6 See Note 7 See Note 5 CHANGE INPUTS CHANGE STATUS STATUS FUNCTION TDR DELAY SIGNAL ESD ACTION ESD MOVE TO INPUT(0)? (ON) - OK?

  • Page 34: Failure Analysis

    Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 Failure Analysis Failure Analysis A single failure in MX, DCS or remote wiring of the OPEN or CLOSE signals could cause unexpected actuator motion if such failure could be interpreted by the MXA as a command signal.

  • Page 35: Instructions, Operation And Maintenance [Iom]

    10 years. 13.3 Estimated Repair Times Flowserve recommends users should maintain spare motors and printed circuit boards on hand to enable rapid repair of any such actuator that is discovered.

  • Page 36: Revision History

    Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 Revision History Revision Date Description 12 Jan 2012 Initial Release 13 Apr 2012 Added SIS assessment section 7 May 2012 Revised section 8 24 April 2013 General revision for submittal to cover inclusion of option boards 2.3/2.4...

  • Page 37: Regulatory Information

    Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 Regulatory Information 15.1 Certification that adds HART network option board with up to SIL3 capable rating flowserve.com FLOWSERVE PROPRIETARY INFORMATION Use or disclosure of this information is subject to the restrictions on the title page of this document...
  • Page 38 Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 FLOWSERVE PROPRIETARY INFORMATION Use or disclosure of this information is subject to the restrictions on the title page of this document...
  • Page 39 Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 15.2 Original certification that added option boards with up to SIL3 capable rating flowserve.com FLOWSERVE PROPRIETARY INFORMATION Use or disclosure of this information is subject to the restrictions on the title page of this document...
  • Page 40 Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 15.3 Original SIL 3 capable certification for MXa actuator FLOWSERVE PROPRIETARY INFORMATION Use or disclosure of this information is subject to the restrictions on the title page of this document...
  • Page 41 Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 This page left blank intentionally. flowserve.com FLOWSERVE PROPRIETARY INFORMATION Use or disclosure of this information is subject to the restrictions on the title page of this document...
  • Page 42 Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 This page left blank intentionally. FLOWSERVE PROPRIETARY INFORMATION Use or disclosure of this information is subject to the restrictions on the title page of this document...
  • Page 43 Limitorque MX Electronic Actuator FCD LMENIM2350-02 A4 – 05/16 This page left blank intentionally. flowserve.com FLOWSERVE PROPRIETARY INFORMATION Use or disclosure of this information is subject to the restrictions on the title page of this document...
  • Page 44 Office A, 7th Floor, Plot No. 32A & B perform its intended function safely during its useful life. However, the purchaser or user of Flowserve products should be aware that Flowserve products might be used in numerous applications under a wide variety of industrial service conditions. Although Flowserve can (and often does) provide general guidelines, it cannot provide specific Ambit IT Parl, Ambit IT Park Road data and warnings for all possible applications.

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