Baker Hughes Masoneilan SVI II ESD User manual

Masoneilan*
SVI*II ESD SIL3 Emergency Shutdown
Device & PST Controller
Quick Start Guide (Rev. M)
BHGE Data Classification: Public

© 2018 Baker Hughes, a GE company, LLC. All rights reserved.
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About this Guide
This Quick Start Guide applies to the following instruments and approved software:
SVI II ESD
with Firmware version 3.1.2 or greater
with ValVue ESD version 1.0 or greater
with GE DPI620 Handheld Communicator with DD published for SVI II ESD
Masoneilan Device Type 203 or 0xCB
with PRM PLUG-IN ValVue ESD version 1.0 or greater
All information contained herein is believed to be accurate at the time of publication and is subject to
change without notice.
The information contained in this manual, in whole or part, shall not be transcribed or copied without
BHGE’s written permission.
In no case does this manual guarantee the merchantability of the positioner or the software or its adapt-
ability to a specific client needs.
Please report any errors or questions about the information in this manual to your local supplier or visit
www.bhge.com.
DISCLAIMER
THESE INSTRUCTIONS PROVIDE THE CUSTOMER/OPERATOR WITH IMPORTANT PROJECT-SPECIFIC REF-
ERENCE INFORMATION IN ADDITION TO THE CUSTOMER/OPERATOR’S NORMAL OPERATION AND MAIN-
TENANCE PROCEDURES. SINCE OPERATION AND MAINTENANCE PHILOSOPHIES VARY, BHGE (BAKER
HUGHES, A GE company LL AND ITS SUBSIDIARIES AND AFFILIATES) DOES NOT ATTEMPT TO DICTATE
SPECIFIC PROCEDURES, BUT TO PROVIDE BASIC LIMITATIONS AND REQUIREMENTS CREATED BY THE
TYPE OF EQUIPMENT PROVIDED.
THESE INSTRUCTIONS ASSUME THAT OPERATORS ALREADY HAVE A GENERAL UNDERSTANDING OF THE
REQUIREMENTS FOR SAFE OPERATION OF MECHANICAL AND ELECTRICAL EQUIPMENT IN POTENTIALLY
HAZARDOUS ENVIRONMENTS. THEREFORE, THESE INSTRUCTIONS SHOULD BE INTERPRETED AND
APPLIED IN CONJUNCTION WITH THE SAFETY RULES AND REGULATIONS APPLICABLE AT THE SITE AND
THE PARTICULAR REQUIREMENTS FOR OPERATION OF OTHER EQUIPMENT AT THE SITE.
THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN EQUIPMENT NOR TO
PROVIDE FOR EVERY POSSIBLE CONTINGENCY TO BE MET IN CONNECTION WITH INSTALLATION, OPERA-
TION OR MAINTENANCE. SHOULD FURTHER INFORMATION BE DESIRED OR SHOULD PARTICULAR PROB-
LEMS ARISE WHICH ARE NOT COVERED SUFFICIENTLY FOR THE CUSTOMER/OPERATOR'S PURPOSES THE
MATTER SHOULD BE REFERRED TO BHGE.
THE RIGHTS, OBLIGATIONS AND LIABILITIES OF BHGE AND THE CUSTOMER/OPERATOR ARE STRICTLY
LIMITED TO THOSE EXPRESSLY PROVIDED IN THE CONTRACT RELATING TO THE SUPPLY OF THE EQUIP-
MENT. NO ADDITIONAL REPRESENTATIONS OR WARRANTIES BY BHGE REGARDING THE EQUIPMENT OR
ITS USE ARE GIVEN OR IMPLIED BY THE ISSUE OF THESE INSTRUCTIONS.
THESE INSTRUCTIONS ARE FURNISHED TO THE CUSTOMER/OPERATOR SOLELY TO ASSIST IN THE INSTAL-
LATION, TESTING, OPERATION, AND/OR MAINTENANCE OF THE EQUIPMENT DESCRIBED. THIS DOCU-
MENT SHALL NOT BE REPRODUCED IN WHOLE OR IN PART TO ANY THIRD PARTY WITHOUT THE WRITTEN
APPROVAL OF BHGE.
Copyright
Copyright 2018 by Baker Hughes, a GE company LLC. All rights reserved.
PN 055201359-999-0000 Rev. M.

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Document Changes
Version/Date Changes
D/05-2012 ES-727 updated.
E/03-2013 References to double-acting removed.
F/08-2013 Added Load Limits section and cross referenced to same from install.
Updated ES-727 to Rev. R.
G/10-2015 Updated ES-727 to Rev. T.
H/12-2015 Updated ES-727 to Rev. U.
Updated safety section with natural gas warnings.
J/09-2016 Updated references to firmware to add 3.1.8.
Changed the download site throughout.
K/03-2017 Added section on Determine Compliance Voltage.
Added section on Burst Mode.
Added flyback diode to Load Limits section.
Changed ES version to V.
L/12-2017 Updated Load Limits section.
Updated ES-727 to Rev. W.
M/01-2018 Updated Load Limits section.

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Contents
Safety Information ..................................................................................................................... 9
Introduction........................................................................................................................... 9
Terms and Abbreviations ........................................................................................ 9
Acronyms .....................................................................................................................10
Documentation Symbols ...............................................................................................11
Product Safety ....................................................................................................................12
Product Support ........................................................................................................13
Related Literature .....................................................................................................13
Reference Standards ..............................................................................................13
Designing an SIF Using an SVI II ESD...................................................................... 14
SVI II ESD Device Description ......................................................................................14
Safety Function .........................................................................................................14
Environmental Limits ..............................................................................................15
Design Verification ...................................................................................................15
SIL Capability ..............................................................................................................15
Connecting the SVI II ESD to the SIS Logic Solver .....................................16
Installation ...........................................................................................................................17
General Requirements ...........................................................................................17
SVI II ESD Installation Configurations ..............................................................17
Physical Location and Placement Guidelines .............................................17
Pneumatic Connections ........................................................................................17
Electrical Connections ............................................................................................17
Operation, Setup, Commissioning ........................................................................... 18
Maintenance .......................................................................................................................18
Diagnostics ..........................................................................................................................18
PST ...................................................................................................................................18
Installation and Maintenance .............................................................................................21
Introduction .........................................................................................................................21
Using the Quick Start Guide .........................................................................................21

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Installation ...........................................................................................................................22
Physical Location and Placement Guidelines .............................................23
SVI II ESD Components ..........................................................................................24
Mounting the SVI II ESD on Rotary Valves .....................................................25
Travel Sensor Alignment .......................................................................................27
Mounting the SVI II ESD with NAMUR Kits .....................................................28
Mounting the SVI II ESD on Reciprocating Valves .....................................30
Checking the Magnet .............................................................................................33
Using ValVue* ESD to Check Magnet Position ............................................33
Checking Actuator, Linkages, or Rotary Adapter ......................................34
Connecting the Tubing and Air Supply ...........................................................35
Wiring the SVI II ESD ................................................................................................40
Powering Up the SVI II ESD ..................................................................................44
Making Connections to the Terminal Board ................................................51
SVI II ESD Maintenance ..................................................................................................52
Repair and Replacement ......................................................................................52
Factory Notification .................................................................................................52
Display Cover Removal and Installation ........................................................53
Setup, Calibration and PST ...................................................................................................55
Overview ...............................................................................................................................55
SVI II ESD Setup ..................................................................................................................55
Pushbuttons and Local Display .........................................................................55
Accessing Pushbuttons .........................................................................................57
Pushbutton Locks and Configuration-Lock Jumper ................................58
Modes of Operation .................................................................................................59
Configuration .............................................................................................................62
Calibration........................................................................................................................... 66
Check-out with a HART® Handheld Communicator ...............................67
Diagnostics ..........................................................................................................................69
Partial Stroke Test Diagnostics ..........................................................................69
Partial Stroke Testing ......................................................................................................70
PST Configuration .....................................................................................................70
Starting PST .................................................................................................................71
Specifications and References ...........................................................................................73
Physical and Operational Specifications ...............................................................73
Hazardous Location Installation ...............................................................................78

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Optional Switch Load Limits ................................................................................................93
General Configuration Notes ......................................................................................93
Checking Switch Operation .........................................................................................96
ValVue Commands ..................................................................................................96
Determining an SVI Positioner Compliance Voltage in a Control System ......97
Compliance Test Set-Up............................................................................................... 97
Burst Mode Operations ..........................................................................................................99

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Masoneilan SVI II ESD Quick Start Guide =| 9
© 2018 Baker Hughes, a GE company, LLC. All rights reserved.
Introduction
This section provides information necessary to design, install, verify and maintain a Safety Instru-
mented Function (SIF) utilizing a Masoneilan Smart Valve Interface, SVI II ESD. This manual pro-
vides necessary requirements for meeting the IEC 61508 or IEC 61511 functional safety
standards.
Terms and Abbreviations
The following terms and abbreviations are related to safety functions of the SVI II ESD and are
used throughout this document.
Safety Freedom from unacceptable risk of harm.
Functional
Safety
The ability of a system to carry out the actions necessary to achieve or to
maintain a defined safe state for the equipment / machinery / plant /
apparatus under control of the system.
Basic
Safety
The equipment must be designed and manufactured such that it protects
against risk of damage to persons by electrical shock and other hazards
and against resulting fire and explosion. The protection must be effective
under all conditions of the nominal operation and under single fault con-
dition.
Safety
Assess-
ment
The investigation to arrive at a judgment - based on evidence - of the
safety achieved by safety-related systems.
Fail-
Safe State
State where the SVI II ESD is de-energized and has exhausted Actuator 1
in a single acting configuration or has caused Actuator 1 to be at an equal
or lower pressure than Actuator 2 in a dual acting configuration.
Fail Safe Failure that causes the valve to go to the defined fail-safe state without a
demand from the process.
Fail 
Dangerous
Failure that does not respond to a demand from the process (i.e. being
unable to go to the defined fail-safe state).
Fail 
Dangerous 
Unde-
tected
Failure that is dangerous and that is not being diagnosed by automatic
stroke testing.
Fail 
Danger-
ous
Detected
Failure that is dangerous but is detected by automatic stroke 
testing.
1. Safety Information

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Fail 
Annunciation 
Undetected
Failure that does not cause a false trip or prevent the safety function
but does cause loss of an automatic diagnostic and is not detected
by another diagnostic.
Fail 
Annunciation
Detected
Failure that does not cause a false trip or prevent the safety function
but does cause loss of an automatic diagnostic or false diagnostic
indication.
Fail No Effect Failure of a component that is part of the safety function but that has
no effect on the safety function.
Low Demand
Mode
Mode where the frequency of demands for operation made on a
safety-related system is no greater than twice the proof test 
frequency.
Acronyms
The following acronyms are related to safety functions of the SVI II ESD and are used throughout
this document.
FMEDA Failure Modes, Effects and Diagnostic Analysis
HFT Hardware Fault Tolerance
MOC Management of Change. These are specific procedures often done
when performing any work activities in compliance with government
regulatory authorities.
PFDavg Average Probability of Failure on Demand
PST Partial Stroke Test, a test used to detect failure modes in the PST Con-
troller, actuator, and valve assembly.
SFF Safe Failure Fraction, the fraction of the overall failure rate of a
device that results in either a safe fault or a diagnosed unsafe fault.
SIF Safety Instrumented Function, a set of equipment intended to reduce
the risk due to a specific hazard (a safety loop).
SIL Safety Integrity Level, discrete level (one out of a possible four) for
specifying the safety integrity requirements of the safety functions to
be allocated to the E/E/PE safety-related systems where Safety
Integrity Level 4 has the highest level of safety integrity and Safety
Integrity Level 1 has the lowest.
SIS Safety Instrumented System – Implementation of one or more Safety
Instrumented Functions. A SIS is composed of any combination of
sensor (s), logic solver (s), and final element (s).

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Documentation Symbols
Conventions used in this manual are as follows:
Italicized letters are used when referencing a term used in the program
display window.
Italics is used for emphasis on important items.
Fields where data is entered or user-entered data is italicized.
Actions performed on buttons, checkboxes, etc. appear bolded. 
For example: Click Done.
SVI II ESD instructions contain WARNINGS, CAUTIONS labels and Notes, where necessary, to
alert you to safety related or other important information. Read the instructions carefully before
installing and maintaining your instrument. Total compliance with all WARNING, and CAUTION
notices is required for safe operation.
Indicates a potentially hazardous situation, which if
not avoided could result in serious injury or death.
Indicates a potentially hazardous situation, which if
not avoided could result in instrument or property
damage, or data loss.
Indicates important facts and conditions.
WARNING
CAUTION
NOTE

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Product Safety
For SVI II ESD positioners intended for use with industrial compressed air or, natural gas systems
only.
NOTE See “Hazardous Location Installation” on page 78 for natural gas
safety information.
Ensure that an adequate pressure relief provision is installed when the application of system
supply pressure could cause peripheral equipment to malfunction. Installation must be in accor-
dance with local and national compressed air and instrumentation codes.
General installation, maintenance or replacement
Products must be installed in compliance with all local and national codes
and standards by qualified personnel using safe site work practices.
Personal Protective Equipment (PPE) must be used per safe site work
practices.
Ensure proper use of fall protection when working at heights, per safe site
work practices. Use appropriate safety equipment and practices to prevent
the dropping of tools or equipment during installation.
Under normal operation, compressed supply gas is vented from the SVI II
ESD to the surrounding area, and may require additional precautions or
specialized installations.
Intrinsically Safe Installation
Products certified for use in intrinsically safe installations MUST BE:
Installed, put into service, used and maintained in compliance with national
and local regulations and in accordance with the recommendations
contained in the relevant standards concerning those environments.
Used only in situations that comply with the certification conditions shown
in this document and after verification of their compatibility with the zone of
intended use and the permitted maximum ambient temperature.
Installed, put into service and maintained by qualified and competent
professionals who have undergone suitable training for instrumentation
used in such areas.
WARNING Before using these products with fluids/compressed gases other
than air or for non-industrial applications, consult the factory.
This product is not intended for use in life support systems.

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WARNING Do not use damaged instruments.
WARNING Installation in poorly ventilated confined areas, with any potential
of gases other than oxygen being present, can lead to a risk of
personnel asphyxiation.
Use only genuine replacement parts which are provided by the manufacturer, to guarantee that
the products comply with the essential safety requirements of the European Directives.
Changes to specifications, structure, and components used may not lead to the revision of this
manual unless such changes affect the function and performance of the product.
Product Support
For detailed product instructions and technical support refer to the SVI II ESD SIL3 Instruction
Manual GEA18946.
Related Literature
Documents related to the SVI II ESD include:
TUV Certificate No. SAS0016/07, Vers. 1.0
Guidelines/References:Safety Integrity Level Selection – Systematic Methods
Including Layer of Protection Analysis, ISBN 1-55617-777-1, ISA
Control System Safety Evaluation and Reliability, 2nd Edition, 
ISBN 1-55617-638-8, ISA
Safety Instrumented Systems Verification, Practical Probabilistic
Calculations, ISBN 1-55617-909-9, ISA
Reference Standards
Functional Safety reference standards related to the SVI II ESD include:
IEC 61508: 2000 – Functional safety of electrical/electronic/programmable
electronic safety-related systems
ANSI/ISA 84.00.01-2004 (IEC 61511 Mod.) Functional Safety – Safety
Instrumented Systems for the Process Industry Sector

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SVI II ESD Device Description
An ESD valve is a valve that is operated to ensure that the process is brought to its safe state.
During normal operation, these ESD valves are typically energized to stay open. In case of an un-
safe situation, the ESD valve is de-energized by the Safety System. The SVI II ESD device performs
this shutdown function for Safety Instrumented Functions (SIF) that require field devices to be
certified for safety related applications according to IEC61508 and is certified by TUV for use up
to SIL3 with a HFT of 0 in low demand applications. It is important to note that the built-in micro-
processor is used for valve diagnostics only. The microprocessor has no direct role in performing
the designated safety function therefore the SVI II ESD is considered a Type A device.
The SVI II ESD is a valve controller that mounts on a pneumatically actuated valve assembly. Its
role is to position an emergency shutdown valve to 0% or 100% with a PFDavg in accordance
with IEC61508 for SIL3 application.
Because of its capability of monitoring data from its embedded sensors, the SVI II ESD is capable
of validating the health of its integral components. Also, with the ability of partially stroking the
ESD valve while in normal operations (energized to stay open); it becomes possible to validate
the health of the valve and actuator assembly. Periodic testing of the ESD valve reduces the PF-
Davg by detecting dangerous failures.
Designing an SIF Using an SVI II ESD
The following must be taken into consideration when designing a SIF (Safety Instrumented Func-
tion) using the SVI II ESD:
“Safety Function” on page 14
“Environmental Limits” on page 15
“Design Verification” on page 15
“SIL Capability” on page 15
“Connecting the SVI II ESD to the SIS Logic Solver” on page 16
“General Requirements” on page 17
Safety Function
When de-energized, the SVI II ESD moves to its fail-safe position. For a single-acting PST control-
ler the safe state is when the port Actuator 1 is exhausted to a pressure that is less than 1 PSIG
(0.069 bar, 6.9 kPa). The valve actuation means must be of a type that automatically moves the
valve to the safe state when the digital valve controller is in its safe state.
The SVI II ESD is intended to be part of final element subsystem as defined per IEC 61508 and the
achieved SIL level of the designed function must be verified by the designer.

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Environmental Limits
The designer of a SIF must check that the product is rated for use within the expected environ-
mental limits as stated in Table 10 on page 73.
Application limits
Application limits for the SVI II ESD installed in a SIF include:
The application of the SVI II ESD is limited for SIF where the safe state is the
de-energized state (shutdown) of the valve. The PST Controller may be
operated with either one of two control signals: 4 - 20 mA or 0 - 24 VDC.
With a 4 - 20 mA control signal, normal operation is with a 20 mA current
loop signal to the PST controller. A shutdown command is issued by taking
the current to 5.6 mA or lower.
With a 0 - 24 VDC control signal, normal operation is with a 24 VDC signal
applied to the PST controller. A shutdown command is issued by interrupting
the loop or taking the voltage signal to 3 VDC or lower.
Design Verification
The design verification criteria for the SIF and the SVI II ESD include:
A detailed Failure Mode, Effects, and Diagnostics Analysis (FMEDA) report is
available from the factory. This report details all failure rates and failure
modes as well as the expected lifetime.
The achieved Safety Integrity Level (SIL) of an entire Safety Instrumented
Function (SIF) design must be verified by the designer via a calculation of
PFDavg considering redundant architectures, proof test interval, proof test
effectiveness, any automatic diagnostics, average repair time and the
specific failure rates of all products included in the SIF. Each subsystem must
be checked to assure compliance with minimum hardware fault tolerance
(HFT) requirements. The exida exSILentia*tool is recommended for this
purpose as it contains accurate models for the SVI II ESD and its failure rates.
When using an SVI II ESD in a redundant configuration, include a common
cause factor of 5% in safety integrity calculations.
The failure rate data listed in the FMEDA report is only valid for the useful life
time of an SVI II ESD. The failure rates increase sometime after this time
period. Reliability calculations based on the data listed in the FMEDA report
for mission times beyond the lifetime may yield results that are too
optimistic, i.e. the calculated Safety Integrity Level will not be achieved.
SIL Capability
The SVI II ESD meets SIL 3 requirements as outlined below.

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Systematic Integrity
The product has met manufacturer design process requirements of Safety Integrity Level (SIL) 3.
These are intended to achieve sufficient integrity against systematic errors of design by the
manufacturer. A Safety Instrumented Function (SIF) designed with this product must not be used
at a SIL level higher than the statement without prior use justification by end user or diverse
technology redundancy in the design.
Random Integrity
The SVI II ESD’s safety critical function is maintained by a Type A Device. Therefore based on the
SFF > 90%, when the SVI II ESD is used as the only component in a final element subassembly, a
design can meet SIL 3 @ HFT=0.
When the final element assembly consists of many components (SVI II ESD, quick exhaust valve,
actuator, isolation valve, etc.) the SIL must be verified for the entire assembly using failure rates
from all components. This analysis must account for any hardware fault tolerance and architec-
ture constraints.
Safety Parameters
For detailed failure rate information refer to the Failure Modes, Effects and Diagnostic Analysis
Report for the SVI II ESD available from the factory.
Connecting the SVI II ESD to the SIS Logic Solver
When connecting the SVI II ESD to the SIS logic solver follow these guidelines:
The SVI II ESD is connected to the safety rated logic solver which is actively
performing the safety function. Connections must be made per the
instructions supplied by the safety rated logic solver.
The output rating of the I/O module must meet or exceed the electrical
specifications of the SVI II ESD as referenced in ES727 (“Hazardous Location
Installation” on page 78).

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General Requirements
The following general requirements for the SVI II ESD must be adhered to:
The system’s response time must be less than process safety time. The SVI II
ESD switches to its fail safe state in less than 100 ms. Response time is
actuator dependent.
You must add the SVI II ESD response time to actuator/valve response to get
overall response time.
All SIS components including the SVI II ESD must be operational before
process start-up. The internal diagnostic test that monitors the SVI II ESD for
faults has a one hour test interval. This test does not partial stroke the valve.
In order to use the PST as an automatic diagnostic tool the PST must be
scheduled (using ValVue ESD) to run at least once per month or ten times
within the expected hazard demand interval whichever comes first. Detailed
failure rate data is specified in the FMEDA report available from the factory.
You must verify that the SVI II ESD is suitable for use in safety applications by
confirming the SVI II ESD’s nameplate is properly marked.
Personnel performing maintenance and testing on the SVI II ESD must be
qualified to do so.
Results from the PST and proof tests must be recorded and reviewed
periodically.
The useful life of the SVI II ESD is discussed in the Failure Modes, Effects and
Diagnostic Analysis Report for the SVI II ESD.
Installation
All issues related to installation are outlined below.
SVI II ESD Installation Configurations
Refer to “SVI II ESD Configurations” on page 41.
Physical Location and Placement Guidelines
Refer to “Physical Location and Placement Guidelines” on page 23.
Pneumatic Connections
Refer to “Pneumatic Connections” on page 35.
Electrical Connections
Refer to“Electrical Connection Guidelines” on page 40

© 2018 Baker Hughes, a GE company, LLC. All rights reserved.
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Operation, Setup, Commissioning
Refer to “Setup, Calibration and PST” on page 55.
Maintenance
Refer to “SVI II ESD Maintenance” on page 52.
Diagnostics
The SVI II ESD provides several types of diagnostic information:
Continuous device diagnostics
Self diagnostics of the pneumatics and the safety function that run every
hour and require no user configuration
Partial Stroke Testing (PST) diagnostics
PST
You can configure and run PST at runtime. For more information on PST refer to “Partial Stroke
Testing” on page 70.

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Proof Test
You can also manually run a proof test to detect failures within an SVI II ESD and ESD valve that
are not detected by any automatic diagnostics of the system. Of main concern are undetected
failures that prevent the safety instrumented function from performing its intended function.
The frequency of proof testing, or the proof test interval, is to be determined in reliability calcu-
lations for the safety instrumented functions for which an SVI II ESD is applied. The proof tests
must be performed more frequently or as frequently as specified in the calculation in order to
maintain the required safety integrity of the safety instrumented function.
The following proof test is recommended. Report any failures that are detected and that compro-
mise functional safety to the factory.
This test detects approximately 99% of possible DU failures in the SVI II ESD (Proof Test Coverage).
The person (s) performing the proof test of an SVI II ESD must be trained in SIS operations, includ-
ing bypass procedures, maintenance and company Management of Change procedures. No
special tools are required.
Table 1: Proof Test Steps
Step Action
1Read the SVI II ESD data record using a HART®handheld device or ValVue ESD
software. Resolve any active faults before proceeding.
2Bypass the valve, or isolate or take other appropriate action to avoid a false trip,
following company Management of Change (MOC) procedures
3Inspect the SVI II ESD for dirty or clogged ports and other physical damage
4De-energize the SVI II ESD and observe that the actuator and valve move. Ener-
gize the SVI II ESD after the valve has moved its full stroke length.
5Inspect the SVI II ESD for dirt, corrosion or excessive moisture. Clean if necessary
and take corrective action to properly clean the air supply. This is done to avoid
incipient failures due to dirty air.
6Record any failures in your company’s SIF inspection database. Restore the loop
to full operation.
7Remove the bypass or otherwise restore normal operation

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