DVG ITVC Series User manual

Intelligent Total
Valve Controller
Document Number Prepared Approved Date Release
IOM-ITVC-LB AA GR 10/02/2016 04
Annex B:
Line Break
Line Break-differential
ITVC Series
Gas Over Oil actuator
with ITVC Line Break

ITVC Series – Intelligent Total Valve Controller IOM-ITVC-LB-04
DVG AUTOMATION S.p.A.
Legal & Operative HQ: 29016 Cortemaggiore (Piacenza) Italy, Via G. Rossetti n° 2
Tel. [phone]; Fax [phone];
FullyPaid In Capital: Euro 1.000.000,00= ISO 9001, ISO 14001, OHSAS 18001 CERTIFIED
REA 167410 - VAT 01494460338
COMPANY SUBJECTTO MANAGEMENT AND COORDINATION BY G.I.V.A. S.P.A.WITH HEADQUARTERS IN RHO (MILAN), RECORDED UNDER NUMBER 02917180172 IN
MILAN'S REGISTER OF COMPANIES
[email protected]t
www.dvgautomation.it SHEET 3 DI 28
DVGITVCSeries–“IntelligentTotalValveController” 
ANNEXB:LineBreakandLineBreak-differential
1 Introduction..........................................................................................................................................5
2 Line Break protection system................................................................................................................6
3 Line Break (LB)......................................................................................................................................6
3.1 Operating mode........................................................................................................................... 7
3.2 Enable/Disable Valve Control........................................................................................................ 8
3.3 Working parameters..................................................................................................................... 8
3.4 Acquisition + ValveControl operating mode................................................................................. 9
3.5 Remote signalling......................................................................................................................... 9
3.6 Local signalling............................................................................................................................10
3.7 Analogue inputs architecture.......................................................................................................10
3.8 Output to drive the SOV ..............................................................................................................10
3.9 CPU redundancy..........................................................................................................................10
3.10 Diagnostics..................................................................................................................................11
3.10.1 CPU diagnostics...................................................................................................................11
3.10.2 Analogue inputs diagnostics.................................................................................................11
3.11 LBmenu in the ITVC HMI.............................................................................................................13
3.11.1 Enable / Disable ValveControl.............................................................................................14
3.11.2 LBparameters .....................................................................................................................15
3.11.3 LBSensor option..................................................................................................................17
3.11.4 LBoptions in the MEASUREMENTmenu of ITVC HMI...........................................................18
4 Line Break differential (LB-d)...............................................................................................................19
4.1 Operating mode..........................................................................................................................19
4.2 CPU redundancy..........................................................................................................................20
4.3 Output to drive the SOV..............................................................................................................20
4.4 Diagnostic ...................................................................................................................................20
4.5 LB-d menu in the ITVC HMI..........................................................................................................21
4.6 LB-dSensoroption ......................................................................................................................21

ITVC Series – Intelligent Total Valve Controller IOM-ITVC-LB-04
DVG AUTOMATION S.p.A.
Legal & Operative HQ: 29016 Cortemaggiore (Piacenza) Italy, Via G. Rossetti n° 2
Tel. [phone]; Fax [phone];
FullyPaid In Capital: Euro 1.000.000,00= ISO 9001, ISO 14001, OHSAS 18001 CERTIFIED
REA 167410 - VAT 01494460338
COMPANY SUBJECTTO MANAGEMENT AND COORDINATION BY G.I.V.A. S.P.A. WITH HEADQUARTERS IN RHO (MILAN), RECORDED UNDER NUMBER 02917180172 IN
MILAN'S REGISTER OF COMPANIES
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4.7 LB-d Enable / Disable...................................................................................................................22
4.8 LB-dparameters..........................................................................................................................23
5 Battery option.....................................................................................................................................24
5.1 Setting options in the ADMINISTRATOR menu.............................................................................25
6 Troubleshooting..................................................................................................................................26
7 Start-up...............................................................................................................................................27
7.1 LB start-up...................................................................................................................................27
7.2 LB-dstart-up................................................................................................................................27
8 InstallationandMaintenance..............................................................................................................27
WARRANTY................................................................................................................................................28
Trade Marks:..............................................................................................................................................28

ITVC Series – Intelligent Total Valve Controller IOM-ITVC-LB-04
DVG AUTOMATION S.p.A.
Legal & Operative HQ: 29016 Cortemaggiore (Piacenza) Italy, Via G. Rossetti n° 2
Tel. [phone]; Fax [phone];
FullyPaid In Capital: Euro 1.000.000,00= ISO 9001, ISO 14001, OHSAS 18001 CERTIFIED
REA 167410 - VAT 01494460338
COMPANY SUBJECTTO MANAGEMENT AND COORDINATION BY G.I.V.A. S.P.A. WITH HEADQUARTERS IN RHO (MILAN), RECORDED UNDER NUMBER 02917180172 IN
MILAN'S REGISTER OF COMPANIES
[email protected]t
www.dvgautomation.it SHEET 5 DI 28
1Introduction
This document, ITVC Annex B contains the information to set and use the Line Break function of the ITVC
Intelligent Total valve Controller. It is supplied to the user together with the manual IOM-ITVC-Basic if the ITVC has
the option “Line Break function”.
The “Annex B: Line Break function” should be considered an integral part of the document IOM-ITVC-Basic
for actuator with Line Break function.
Refer to document “IOM-ITVC-Basic” for the complete Installation, Operation and Maintenance instructions of
the ITVC
The “Annex B: Line Break function”, together with the “IOM-ITVC-Basic” is an integral part of the apparatus
and must be carefully read, understood and consulted before use and must be retained for future reference
WARNING!
Do not install, operate, or maintain an ITVC without first being fully trained and qualified in valve,
actuator and accessory installation, operation and maintenance, and carefully reading and
understanding the contents of this manual, including all safety cautions and warnings. For any
questions regarding these instructions, contact the factory before proceeding.
With reference to the manual IOM-ITVC-Basic, chapter ITVC HMI, paragraph HOME page, the Line Break function
is available only if the ITVC display shows the icon or .
The icon signals that the Line Break function is available and working according to the settings, but the output to
drive the actuator in safe position is disabled. No action is done by the ITVC to execute the safe action.
The icon signals that the execution of the safe action is enabled. If one of conditions described in the next
paragraphs occurs, the ITVC will drive actuator and process valve in safe position.
The Line Break pages in the HMI menu allow setting the working parameters.
In general the ITVC with Line Break function is fitted with an optional backup battery pack of rechargeable lithium-ion
batteries. The icon signals the charge level of the batteries. By the battery, the ITVC can work properly even if the
main electrical power fails (see Battery option paragraph)
The below figures show the HOME page, standard, HPU and HIPPS types of the ITVC HMI. Refer to IOM-ITVC-
Basic, ITVC HMI chapter, to view the HOME pages features. Refer to the above IOM to find the instructions relevant
to MENU chart and menu operations.
The procedures described in this document use HOME page standard type.
The procedures to navigate in the menu are the same if the HOME page is HPU and HIPPS type. Only the HOME
page changes.
LB icon LB icon LB icon
Battery icon Battery icon Battery icon
The icon
changes in if
the Line Break
function is enabled
to carry out the
safe action
HOME page standard type
HOME page HPU
type
HOME page HIPPS
type
ITVC
equipped
with
battery pack
Standard or extended endurance battery pack
(Rechargeable lithium-ion batteries)

ITVC Series – Intelligent Total Valve Controller IOM-ITVC-LB-04
DVG AUTOMATION S.p.A.
Legal & Operative HQ: 29016 Cortemaggiore (Piacenza) Italy, Via G. Rossetti n° 2
Tel. [phone]; Fax [phone];
FullyPaid In Capital: Euro 1.000.000,00= ISO 9001, ISO 14001, OHSAS 18001 CERTIFIED
REA 167410 - VAT 01494460338
COMPANY SUBJECTTO MANAGEMENT AND COORDINATION BY G.I.V.A. S.P.A. WITH HEADQUARTERS IN RHO (MILAN), RECORDED UNDER NUMBER 02917180172 IN
MILAN'S REGISTER OF COMPANIES
[email protected]t
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2Line Break protection system
It is a system to be installed at a pipeline site to monitor the pipeline integrity and prevent dangerous conditions due to
abnormal pressures or pressure changes. Basically it is made of pressure transmitters, actuator, process valve and ITVC
logic solver. According to the system configuration the ITVC logic solver can be set to work as
Line Break: If the ITVC detects an abnormal pressure drop rate or a dangerous pressure in the pipeline drives the
actuator to close the process valve
or alternatively
Line Break-differential: If the ITVC detects a differential pressure outside the permissible limits, across the
process valve, drives the valve in safe position. Three options are available: stayput, close, open
In this manual, Line Break function will be abbreviated by LB, and Line Break-differential by LB-d
3Line Break (LB)
This function protects the pipeline in three ways:
Pressure drop rate higher than a configurable limit
Pressure higher than a configurable limit
Pressure less than a configurable limit
If the ITVC detects one of the above condition drives actuator and valve in closure.
Its features include logic solver function with redundancy of CPU’s and voting mechanism, acquisition and record of
pipeline pressure trends, local and remote control to open/close the process valve, suitability for gas and liquids
applications.
It can be set to work in 1oo1, 1oo2, 1oo3 and 2oo3 configuration. The below figures show the 1oo1 and 2oo3
configurations
Process Valve
Actuator
Pressure sensor
Pipeline
1oo1 configuration
Pt1
Solenoid
Valve
ITVC
SOV1
Gas and
liquids
Process Valve/s
Actuator
/s
Pressure sensors
Pipeline
2oo3 configuration
Pt1
Pt2
Pt3
SOV1
SOV2
ITVC
Solenoid
Valves
Gas and
liquids
The options in
Line Break menu
page of ITVC HMI allows:
To set the type of Line Break function (LB or LB-d)
To Disable/Enable the safe action execution (if the condition
to do it occurs)
To set the sensor architecture and working setpoints

ITVC Series – Intelligent Total Valve Controller IOM-ITVC-LB-04
DVG AUTOMATION S.p.A.
Legal & Operative HQ: 29016 Cortemaggiore (Piacenza) Italy, Via G. Rossetti n° 2
Tel. [phone]; Fax [phone];
FullyPaid In Capital: Euro 1.000.000,00= ISO 9001, ISO 14001, OHSAS 18001 CERTIFIED
REA 167410 - VAT 01494460338
COMPANY SUBJECTTO MANAGEMENT AND COORDINATION BY G.I.V.A. S.P.A. WITH HEADQUARTERS IN RHO (MILAN), RECORDED UNDER NUMBER 02917180172 IN
MILAN'S REGISTER OF COMPANIES
[email protected]t
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3.1 Operating mode
Three operating modes are available:
Acquisition : the ITVC Line Break does not carry out any action to stroke the process valve, the Valve
Control is off and forced to “Disable”. The icon in the HOME page of display is . Acquisition of
analogue pressure channels is continuously done and the values are visible as instantaneous measures and 24h
graphs in the ITVC local display (see IOM-ITVC Basic, Visualization of pressures, Instantaneous measures
and Historical data sub-menus paragraphs). The ITVC monitors two pressure data, “Pressure increase / hour”
and “Pressure decrease / hour”. If one the above measures exceeds the parameters “Max pressure increase”
and “Max pressure decrease”, the ITVC raises a Warning, the LED of the pushbutton lights-up,
fuchsia colour, and the display shows the icon . After few minutes, and if the pressure remains stable, the
warning is cleared but the type of warning with date and time is memorized in the ITVC permanent memory
and is visible in the “Line Break warning” option of the Measurement menu. The measured “maximum
increase and decrease / hour” are visible in the operating mode “Monitor”. The action of parameters “Max
pressure increase” and “Max pressure decrease” can be inhibited by the option “Available/Not available” in the
setting operations. If the setting is “Not available”, no warning is raised. Open/Close, ESD actuator controls
are available.
Acquisition + Valve Control : in this mode all features of Acquisition mode are actives, in addition, if the
Valve Control is set “Enable” and if one of the “Pressure events” listed below occurs and persists for a
configurable time (Delay action), the ITVC carries out the Valve Control, that is “to energize the SOV to
stroke actuator and process valve in close position”. An alarm is generated, the LED of the pushbutton
lights-up, red colour, and the icon appears on the display. In the option “Line Break events” of the
Measurement menu is available the event history with date, time and 24 hours graph.
oPressure events:
the pipeline pressure exceeds the configured maximum pressure (reaction time 400ms)
the pipeline pressure is less than the configured minimum pressure (reaction time 400ms)
the pipeline pressure drop / minute exceeds the configured pressure drop rate (reaction time 400ms)
If the “Pressure event” disappears in the “Delay action” time, no action is done.
Once the Valve Control ends, Open/Close actuator control are inhibited (in the paragraph “Acquisition +
Valve Control mode is described the procedure to restart the operation and clear the alarm).
In general, the “safe position” is “valve closed”, but it is configurable by the procedure described in the
paragraph ESD shutdown, chapter “Setup, Administrator menu” of manual IOM-ITVC-Basic.
Monitor : all acquisition features of “Acquisition” mode are available,
Valve Control is off and forced to “Disable”, check of “Pressure increase / hour”
and “Pressure decrease / hour” is done as in Acquisition mode, but if the test
fails, the ITVC does not raise any warning. The measured “maximum pressure
increase / hour” and “maximum pressure decrease / hour” are visible in the local
display of the HMI and can be cleared by the configuration options of the menu.
The read values can be used to set the working parameters of Line Break function.
The icon in the HOME page of display is . Open/Close ESD actuator controls are available.
A

ITVC Series – Intelligent Total Valve Controller IOM-ITVC-LB-04
DVG AUTOMATION S.p.A.
Legal & Operative HQ: 29016 Cortemaggiore (Piacenza) Italy, Via G. Rossetti n° 2
Tel. [phone]; Fax [phone];
FullyPaid In Capital: Euro 1.000.000,00= ISO 9001, ISO 14001, OHSAS 18001 CERTIFIED
REA 167410 - VAT 01494460338
COMPANY SUBJECTTO MANAGEMENT AND COORDINATION BY G.I.V.A. S.P.A. WITH HEADQUARTERS IN RHO (MILAN), RECORDED UNDER NUMBER 02917180172 IN
MILAN'S REGISTER OF COMPANIES
[email protected]t
www.dvgautomation.it SHEET 8 DI 28
3.2 Enable/Disable Valve Control
If the operating mode is “Acquisition + Valve Control”, the option “Enable” = ON = “ “ in the Line Break menu
page, enables the ITVC to perform the Valve Control (if a Pressure event occurs). The icon in the HOME page
of display changes in .
On the contrary, the option “Disable” = ON = “ “ inhibits the Valve Control even
if a pressure event occurs . The icon in the HOME page of display changes from
to .
In the operating modes “Acquisition” and “Monitor” the icon
in the HOME page of display is and the “Enable” option
in the LB page is forced to OFF = .
The paragraph “Enable/Disable VC” shows the procedure to set the Enable/ Disable.
3.3 Working parameters
The paragraph LB parameters shows the procedure to set the working
parameters of the Line Break function by the ITVC HMI.
The figure “LB parameters” shows the list of parameters to set.
Max pressure: the parameter sets the pipeline maximum working pressure.
If the measured pressure exceeds the “Max pressure” for the time “Delay action”,
a “Pressure event” occurs. If the operating mode is “Acquisition + Valve
Control, “Enable” is “ =ON “, the ITVC Line Break energizes the SOV to close
actuator and process valve.
Min pressure: the parameter sets the pipeline minimum working pressure.
If the measured pressure is less than “Min pressure” for the time “Delay action”, a “Pressure event” occurs. If the
operating mode is “Acquisition + Valve Control” and Enable” is “ =ON “, the ITVC Line Break energizes the SOV
to close actuator and process valve.
Pressure drop in ACQVC mode: the parameter sets the allowable max pipeline pressure drop /minute. The action of
the parameter can be inhibited by the option “Not Available/ Available” in the setting procedure.
If the setting is “available” and the measured pipeline pressure drop / minute exceeds the above parameter for the time
“Delay action”, a “Pressure event” occurs. If the operating mode is “Acquisition + Valve Control” and Enable” is “
=ON “, the ITVC Line Break energizes the SOV to close actuator and process valve. If the setting is “not available”, the
ITVC Line Break does not carry out any action in case of pipeline pressure drop.
Delay action: it is the time between the detection of the “Pressure events” described in the “Operating mode”
paragraph and the start of the action to close the process valve. If the pressure event disappears during the time “Delay
action”, the ITVC Line Break does not carry out any action to move the process valve.
Operating mode: it allows setting the Line Break operating mode, as described in the previous paragraph “Operating
mode”. Three operating modes are available: Acquisition, Acquisition + Valve Control, Monitor
Maximum pressure increase: it sets the allowable maximum increase in pressure / hour. The parameter can be
inhibited by the option “available/not available” in the setting procedure. If the measured “pressure increase / hour”
exceeds the above parameter, the parameters is set “available”, and the operating mode is “Acquisition” or “Acquisition
+ Valve Control”, the ITVC Line Break raises a Warning, but the SOV is not energized and no action is carried out
to close the process valve. In “Monitor” operating mode, no warning is generated and the measured maximum pressure
increase can be viewed in the Monitor page of the menu.
LB
parameters
LB page
= ON
= OFF

ITVC Series – Intelligent Total Valve Controller IOM-ITVC-LB-04
DVG AUTOMATION S.p.A.
Legal & Operative HQ: 29016 Cortemaggiore (Piacenza) Italy, Via G. Rossetti n° 2
Tel. [phone]; Fax [phone];
FullyPaid In Capital: Euro 1.000.000,00= ISO 9001, ISO 14001, OHSAS 18001 CERTIFIED
REA 167410 - VAT 01494460338
COMPANY SUBJECTTO MANAGEMENT AND COORDINATION BY G.I.V.A. S.P.A. WITH HEADQUARTERS IN RHO (MILAN), RECORDED UNDER NUMBER 02917180172 IN
MILAN'S REGISTER OF COMPANIES
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Maximum pressure decrease: it sets the allowable maximum decrease in pressure / hour. The parameter can be
inhibited by the option “available/not available” in the setting procedure. If the measured “pressure decrease / hour”
exceeds the above parameter and the parameter is set “available”, the ITVC Line Break raises a Warning, but the SOV
is not energized and no action is carried out to close the process valve. In “Monitor” operating mode, no warning is
generated and the measured maximum pressure decrease can be viewed in the Monitor page of the menu.
3.4 Acquisition + Valve Control operating mode
To start the LB operation
The Line Break carries out the Valve Control if the operating mode is “Acquisition + Valve Control” and only if
“Enable is = ”. The paragraphs “Enable/Disable VC” shows the procedures to Enable the Valve Control. The icon
in the HOME page of the display switches from to . The local and remote Open/Close and ESD commands
are available. The ITVC Line Break continuously acquires and measures the pipeline pressure. If one of the “Pressure
events” described in the previous paragraph “Operating mode”occurs and persists for the time “Delay action”, the
ITVC Line Break carries out the “Valve Control”, that means: to energize the SOV and stroke the actuator and the
process valve in closure (safe position). After having closed the process valve the Valve Control switches in “Disable”
and any open/close command is inhibited. The data of the “pressure event” (date, type of event, 24h pressure graph)
are memorized in the ITVC permanent memory and can be viewed in the Measurement menu of the ITVC HMI. The
icon in the HOME page of the display switches from to . ITVC signals Alarm and any Open and Close
command is off.
If the Pressure event disappears within the time “Delay action”, no action is done.
To restart LB operation after a Valve Control:
restore the correct pressure in the pipeline
set “Enable = ” in the Line Break parameters
re-open the actuator by the local or remote open command
To re-open the valve without restoring the correct pressure in the pipeline:
set Acquisition or Monitor control mode. The Alarm disappears, exit from MENU mode.
move the valve by the local or remote open/close commands
set the Acquisition + Valve Control mode
when the pipeline pressure is correct, set the Line Break option “Enable = ”
To set in OFF the Valve Control function
set Acquisition or Monitor operating mode. In the above modes the Valve Control is OFF, the option “Disable
is = “ and “Enable is = “ .
3.5 Remote signalling
In Acquisition + Valve Control mode and Enable = , the Monitor Relay switches over when ITVC carries out the
Valve Control.
The auxiliary output relays R1,…,R4 can be individually set to signal: Max pressure increase, Max pressure decrease,
LB on=Enable, High LB pressure, Low LB pressure, Max pressure drop. The paragraphs “Output signalling relays” and
“Output relays” in the IOM-ITVC-Basic give the procedure to set the above relays.

ITVC Series – Intelligent Total Valve Controller IOM-ITVC-LB-04
DVG AUTOMATION S.p.A.
Legal & Operative HQ: 29016 Cortemaggiore (Piacenza) Italy, Via G. Rossetti n° 2
Tel. [phone]; Fax [phone];
FullyPaid In Capital: Euro 1.000.000,00= ISO 9001, ISO 14001, OHSAS 18001 CERTIFIED
REA 167410 - VAT 01494460338
COMPANY SUBJECTTO MANAGEMENT AND COORDINATION BY G.I.V.A. S.P.A. WITH HEADQUARTERS IN RHO (MILAN), RECORDED UNDER NUMBER 02917180172 IN
MILAN'S REGISTER OF COMPANIES
[email protected]t
www.dvgautomation.it SHEET 10 DI 28
3.6 Local signalling
In “Acquisition” and “Monitor” operating modes, the HOME page of the display shows the icon .
In “Acquisition + Valve Control” mode and Disable = , the HOME page of the display shows the icon .
In “Acquisition + Valve Control” mode and Enable = , the HOME page of the display shows the icon . If Valve
Control is performed, the ITVC signals Alarm by the red LED of the pushbutton , and the display of the HOME
page shows the icon . The Alarm page shows the message
“High press limit or Low press limit or Press drop”, “Linebreak action”, Safety action LB, and Micro 2 alarm
(see the paragraph Visualization of Alarms and Warnings in the document IOM-ITVC-Basic).
In “Acquisition” and in “Acquisition + Valve Control” modes, the conditions “Pressure increase and decrease / hour >
Max pressure increase/decrease” are signalled by Warning. The LED of the pushbutton is on, fuchsia colour, and
the display shows the icon . The Warning page of the display shows the message “Max pressure increase” or “Max
pressure decrease”. In Monitor operating mode the measured “Max pressure increase and decrease / hour” can be
viewed. The clear option in the above page resets the displayed values.
The option “Line Break Events” in the Measurement menu shows the list of the “Pressure events” with date and
time and the 24 hours graphs.
The option “Line Break Warnings” in the Measurement menu shows the list of the warnings with date and time. No
graph is available.
3.7 Analogue inputs architecture
The option “Sensor” in the Line Break menu page allows setting the architecture
of the analogue inputs connected to the pipeline pressure transmitters .
3 modes are available: 1oo1, 1oo2, 2oo3 and 1oo3.
1oo1 mode: one only pressure transmitter, only Sensor 1 or 2 or 3 = = ON,
no voting mechanism, one only analogue input channel
1oo2 mode: two pressure transmitters, Sensor 1-2 or 1-3 or 2-3 = = ON,
voting mechanism, two analogue input channels
2oo3 mode: three pressure transmitters, Sensor 1-2-3 = = ON,
voting mechanism, three analogue input channels
1oo3 mode: three pressure transmitters, Sensor 1-2-3 = = ON,
voting mechanism, three analogue input channels,
“1oo3 operating mode” = = ON
The analogue input channels should be previously enabled/disabled by the
Setup, Administrator, Analog inputs menu (see document IOM-ITVC-Basic).
The next paragraph “Diagnostics” describes the behaviour in case of failure.
3.8 Output to drive the SOV
According to the user request, the ITVC can be configured to control one or two SOV’s. ITVC functions include the
test of electrical continuity and absence of short-circuit of coil of SOV’s. It is described in the IOM-ITVC-Basic,
paragraph “Test of coil of Solenoid Operated Valves” and in the procedures “Coil test” and “Test coil absorption”,
Setup chapter, Administrator menu. Any fault must be detected three consecutive times, before confirmation.
3.9 CPU redundancy
Line Break and emergency safety functions are managed by two independent CPU’s working in parallel, in particular
they manage input reading, logic processing and output enabling.
A
LB
page
LB sensor
= ON
= OFF