Emerson El-O-Matic E Series Instruction Manual

SIL Safety Manual
DOC.SILM.EEP.EN Rev. 0
April 2017
EL-O-Matic E and P Series Pneumatic Actuator
SIL Safety Manual
schaal 1:1
EL MaticTM
EL MaticTM

EL-O-Matic E and P Series
DOC.SILM.EEP.EN Rev. 0
Table of Contents
April 2017
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Table of Contents
Table of Contents
Section 1: Functional Specification ���������������������������������������1
Section 2: Configuration of the Product ��������������������������������2
Section 3: Service Condition Limitations �������������������������������3
Section 4: Expected Lifetime �������������������������������������������������5
Section 5: Failure Modes and Estimated Failure Rates �����������6
Section 6: Installation and Site Acceptance Procedure ����������7
Section 7: Periodic Test and Maintenance Requirements �������8
7.1 General...................................................................................................... 8
7.2 Full-Stroke Test .......................................................................................... 8
7.3 Partial-Stroke Test...................................................................................... 9
7.4 Proof Test and Periodic Maintenance.......................................................... 9
Section 8: Hardware Fault Tolerance �����������������������������������10
Section 9: Classification ������������������������������������������������������11
Section 10: Safe Failure Fraction �������������������������������������������12
Section 11: Mean Repair Time ����������������������������������������������13

Functional Specification
Section 1: Functional Specication
The safety function for EL-O-Matic E and P Series pneumatic actuator is dened as follows:
Double-Acting Scenario:
a. When an unsafe condition is detected in a plant by a process sensor, the
controller, via actuator control system, drives the Actuator to close the
shut-down valve, depressurizing (if under pressure) the Opening side of
the actuator and pressurizing the Closing side of the actuator.
b. When an unsafe condition is detected in a plant by a process sensor, the
controller, via actuator control system drives the Actuator to open the
blow-down valve, depressurizing (if under pressure ) the Closing side
of the pneumatic actuator and pressurizing the Opening side of the
pneumatic actuator.
Single-Acting Scenario:
a. When an unsafe condition is detected in a plant by a process sensor, the
controller, via actuator control system drives the Actuator to rotate with
sufcient torque to move a valve to its fail-safe state when hold-position
air pressure is released.
The EL-O-Matic E and P Series brand Actuator Selection Procedure provides functional
denition with specics on input variables and performance.
In any case, the choice of the safety function to be implemented is responsibility of the
system integrator.
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Section 1: Functional Specification

Configuration of the Product
Section 2: Conguration of the Product
The EL-O-Matic E and P Series are pneumatically operated actuators designed to operate
Ball / Plug / Buttery valves, automation of louvers and dampers & automation of any
quarter-turn mechanism. Both the double-acting and single-acting (spring-return) versions
of the EL-O-Matic E and P Series pneumatic actuators are designed in such a way that there
are no moving parts on the outside (with the exception of the position indicator). This
makes them safe, easy to install and virtually maintenance free.
For further details about actuator congurations, please refer to the EL-O-Matic E and
P Series product data sheets, Quick Reference Guide and Installation, Operation and
Maintenance manual.
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Section 2: Configuration of the Product

Service Condition Limitations (Limitation of Use)
Section 3: Service Condition Limitations
(Limitation of Use)
The operating capabilities are listed below:
• Maximum Operating Pressure:
— Pneumatic Service
— Up to 8 Barg (116 PSIg)
• Ambient Temperature:
Temperature extremes require different solutions to maintain actuator operational
integrity and reliability. For each EL-O-Matic E and P Series actuator is available in
three different temperature executions.
— -20°C to +80°C (-4°F to +176°F) Standard temperature
— -20°C to +120°C (-4°F to +248°F) High Temperature
— -40°C to +80°C (-40°F to +176°F) Low Temperature
• Torque Output Range:
— Double-Acting EL-O-Matic E and P Series actuators, requiring pressure to
rotate in either direction, are available with a torque range between 4.8
Nm (42 lbf.in) and 6,619 Nm (58,583 lbf.in)
— The EL-O-Matic E and P Series spring-return models require pressure in
only one direction of travel and are suitable for air-fail close and air-fail to
open applications without modication. These models are available with a
spring end torque between 4.6 Nm (41 lbf.in) and 1958 Nm (17,330 lbf.in)
• Safety Function:
For spring-return models, the safety function is self-evident performed by the
springs. The safety function of double-acting models shall be performed by the
A-port. The failure rates in Section 5 are valid only for this conguration.
NOTE:
This product is only intended for use in large-scale xed installations excluded from the
scope of Directive 2011/65/EU on the restriction of the use of certain hazardous substances
in electrical and electronic equipment (RoHS 2).
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Section 3: Service Condition Limitations (Limitation of Use)

Service Condition Limitations (Limitation of Use)
Figure 1 Use the A-Port for Safety Related Systems on Double-Acting Actuators
Data sheet
Sheet No.:
Date: November 2009
www.El-O-matic.com
Copyright © Emerson Process Management. The information in this document is subject to change without notice.
Updated data sheets can be obtained from our website www.El-O-Matic.com or from your nearest Valve Automation Center USA : [phone] Europe : [phone] Asia-Pacific: [phone]
TM
AB
AB
AB
AB
A-port pressurized
B-port pressurized
Pistons
Shaft
A-port pressurized
B-port pressurized
B-port pressurized
A-port pressurized
B-port pressurized
A-port pressurized
1.503 Rev. A DOUBLE ACTING ACTUATOR ASSEMBLY MODES E/P
B
SHAFT TURNED 90°
(from standard)
STANDARD
DC
MOUNTING ACROSS LINE
MOUNTING IN LINE
MOUNTING IN LINE
MOUNTING ACROSS LINE
SHAFT TURNED 90°
PISTONS TURNED 180°
(from standard)
PISTONS TURNED 180°
(from standard)
(OPTIONAL L1/LF) LIMIT STOPS WILL ADJUST THE VALVE AT OPEN POSITION
(OPTIONAL L1/LF) LIMIT STOPS WILL ADJUST THE VALVE AT CLOSED POSITION
All views are from above
Pistons are shown in inner position
A
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Section 3: Service Condition Limitations (Limitation of Use)

Expected Lifetime
Section 4: Expected Lifetime
Actuator lifetime (for which failure rates indicated in Par. 5 are ensured) strongly depends
on operating conditions.
For normal service conditions, EL-O-Matic E and P Series actuators can be in good
conditions also after more than 10 years with planned minimum maintenance. Normal
working life is the number of cycles as dened in Table 1 of EN 15714-3.
EL-O-Matic E and P Series carry a warranty period of:
• 18 months after delivery if properly stored in conditions that we declare or
• 12 months after installation on site.
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Section 4: Expected Lifetime

Failure Modes and Estimated Failure Rates
Section 5: Failure Modes and Estimated
Failure Rates
Table 1� Failure Rates – EL-O-Matic E-Serie Pneumatic Actuator
Failure Category Failure Rate (in FIT)
Spring-Return Double-Acting
Fail Safe 76 0
Fail Dangerous Undetected 342 362
No Effect 1550 1285
Table 2� Failure Rates – EL-O-Matic P-Serie Pneumatic Actuator
Failure Category Failure Rate (in FIT)
Spring-Return Double-Acting
Fail Safe 80 0
Fail Dangerous Undetected 559 465
No Effect 1993 1265
The failure rates for the EL-O-Matic E and P Series pneumatic actuator when performing
partial valve stroke testing are listed in the table below:
Table 3� Failure Rates – EL-O-Matic E-Serie Pneumatic Actuator with partial valve stroke testing
Failure Category Failure Rate (in FIT)
Spring-Return Double-Acting
Fail Safe 76 0
Fail Dangerous Detected 225 201
Fail Dangerous Undetected 117 161
No Effect 1550 1285
Table 4� Failure Rates – EL-O-Matic P-Serie Pneumatic Actuator with partial valve stroke testing
Failure Category Failure Rate (in FIT)
Spring-Return Double-Acting
Fail Safe 80 0
Fail Dangerous Detected 370 256
Fail Dangerous Undetected 189 209
No Effect 1993 1265
NOTICE
No internal diagnostics is included in the device. These values are valid when taken in
account the maintenance interval and procedure described in Section 7, and for the
expected lifetime dened in Section 4.
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Section 5: Failure Modes and Estimated Failure Rates

Installation and Site Acceptance Procedure
Section 6: Installation and Site
Acceptance Procedure
Any necessary installation and site acceptance procedures are discussed in the EL-O-Matic
E and P Series actuators Installation, Operation and Maintenance manual. The Installation,
Operation and Maintenance manual denes exercising of the actuator after installation and
denes testing after maintenance.
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Section 6: Installation and Site Acceptance Procedure

Periodic Test and Maintenance Requirements
Section 7: Periodic Test and
Maintenance Requirements
7�1 General
Please consider that the information in this paragraph are relevant only in regards of
Reliability Tests; please refer to Doc. Installation, Operation and Maintenance manual for
detailed information about product maintenance, handling and storage.
Diagnostic tests may be made to increase the system reliability (Full-Stroke or Partial-
Stroke Test).
“On site” tests depend on Project/Plant facilities/requirements; however, a functional test
must be executed on site, prior actuator operation.
7�2 Full-Stroke Test
The “Full-Stroke Test” (“On-line”) must be performed to satisfy the PFDAVG (average
probability of failure on demand) value.
The full-test frequencies will be dened by the nal integrator in relation to the dened SIL
level to achieve.
• Procedure:
— Operate the Actuator/Valve assembly for No. 2 open/close complete
cycles with complete closing of the valve.
— Verify the Correct performing of open – close manoeuvre (for example,
check locally, or automatically via Logic solver, the correct movement of
the actuator/valve).
Considering the application of the above described Full-Stroke Test procedure, the “Test
Coverage” can be considered 99%.
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Section 7: Periodic Test and Maintenance Requirements

Periodic Test and Maintenance Requirements
7�3 Partial-Stroke Test
The “Partial-Stroke Test” (“On-line”) can be performed to improve the PFDAVG value.
A typical partial-stroke value is 15% of the stroke.
The “Partial-Stroke Test” (“On line”) can be performed to satisfy PFDAVG (average
probability of failure on demand) value.
• Recommended Test Interval = 1 to 3 months.
• Procedure:
— Operate the Actuator/Valve assembly for No 1 open/close cycles 15/20%
of the stroke.
— Verify the Correct performing of partial-stroke operation (for example,
check locally, or automatically via Logic solver, or via the PST system the
correct movement of the actuator/valve till 15/20% of the stroke).
The above parameters to check will depend from the partial-stroke test system available.
Considering the application of the above described Partial-Stroke Test procedure, the
“Diagnostic Coverage” is >90 %.
7�4 Proof Test and Periodic Maintenance
We advise to perform the following checks upon each proof test interval complying with
the rules and regulations of the country of nal installation:
• Visually check the entire actuator as well as the control system (where foreseen).
• Ensure there are no leaks on the actuator parts under pressure.
• Check pneumatic connections for leaks. Tighten tube ttings as required.
• Check if manual override (where foreseen) is regular.
• Check if pneumatic lter cartridge (where foreseen) is sound and lter bowl (where
foreseen) has been cleaned properly.
• Check the setting of the relief valves (where foreseen).
• Verify that the power uid supply pressure value is within the required range.
• Remove built-up dust and dirt from all actuator surfaces.
• Inspect actuator paint work for damages to ensure continued corrosion protection.
Touch-up as required in accordance with the applicable paint specication.
• Operate the Actuator/Valve assembly for No 2 open/close complete cycles with
complete closing of the valve.
• Verify the correct performing of open – close operations (for example, check
locally, or automatically via Logic solver, the correct movement of the actuator).
The Installation, Operation and Maintenance manual denes a minimum maintenance
interval after 500.000 cycles for the EL-O-Matic E and P Series actuators. This addresses
components that may have age related degradation. When the maintenance interval has
elapsed a complete overhaul of the actuator is required.
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Section 7: Periodic Test and Maintenance Requirements

Hardware Fault Tolerance
Section 8: Hardware Fault Tolerance
The HFT of the device is 0.
The requirements of minimum hardware fault tolerance (HFT) according to Tab.6 of IEC
61511-1 have to be observed but, as long as has been performed an assessment report
fully in compliance with IEC 61508 part 1 to7, alternative fault tolerance requirements
have to be considered applicable according to Table 2 of IEC 61508-2 as per par. 11.4.5
of IEC 61511-1.
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Section 8: Hardware Fault Tolerance

Classification
Section 9: Classication
The equipment is classied Type A according to IEC 61508-2.
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Section 9: Classification

Safe Failure Fraction
Section 10: Safe Failure Fraction
SFF=0 without external diagnostic tests.
SFF>0 with external diagnostic tests, carried out according to denition 3.8.7 of IEC 61508-4.
• SFF = 91% with Partial-Stroke Test.
• SFF = 99% with Full-Stroke Test.
The SFF shall be evaluated for the entire nal element sub-system.
The diagnostic test shall be performed considerably more often than the demand of the
safety function.
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Section 10: Safe Failure Fraction

Mean Repair Time
Section 11: Mean Repair Time
For sizes E12 to size E600 the MRT of the device is 1 hour.
For sizes E950 E1600, P2500 and P4000 the MRT of the device is 2 hours.
NOTICE
The MRT is estimated considering availability of skilled personnel for maintenance, spare
parts and adequate tools and materials on site (that is, it encompasses the effective time to
repair and the time before the component is put back into operation).
Procedures to repair or replace the EL-O-Matic E and P Series actuators are provided in the
respective Installation, Operation and Maintenance manual. Please refer to the Installation,
Operation and Maintenance manual for any tools required for repair and replacement and
required competency of technicians. Maintenance and subsequent test procedures are
also covered in the Installation, Operation and Maintenance manual. Any failures, identied
by the end-user during maintenance, repair or proof testing, that potentially impact the
functional safety of the EL-O-Matic E and P Series actuators should be reported back to
Valve Automation Customer Service Coordinator.
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Section 11: Mean Repair Time

For complete list of sales and manufacturing sites, please visit
www.emerson.com/actuationtechnologieslocations or contact us at
info.actuationtechnologie[email protected]om
World Area Configuration Centers (WACC) offer sales support, service,
inventory and commissioning to our global customers.
Choose the WACC or sales office nearest you:
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USA
T [phone]
F [phone]
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Building #230
Székesfehérvár 8000
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T [phone]
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www.emerson.com/el-o-matic
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EL-O-MaticTM is a mark of one of the Emerson family of companies.
All other marks are property of their respective owners.
The contents of this publication are presented for information purposes
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they are not to be construed as warranties or guarantees, express or
implied, regarding the products or services described herein or their use
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are available on request. We reserve the right to modify or improve the
designs or specifications of our products at any time without notice.
EL MaticTM
EL MaticTM