KLAY-INSTRUMENTS 8000 Series User guide

SAFETY MANUAL
SERIES 8000 AND HYDROBAR
Manufactured by:
www.klay.nl
Contents
Nijverheidsweg 5
P.O. Box 13
Tel: [phone]
Fax: [phone]
7991 CZ DWINGELOO
7990 AA DWINGELOO
The Netherlands
E-mail: [email protected]

Functional safety manual –Series 8000 and Hydrobar
SM-EN-8000/09-2013/01 Page 1
1. Functional Safety............................................................................................................................. 2
1.1 Scope ....................................................................................................................................... 2
1.2 Application area ...................................................................................................................... 2
1.3 Safety function ........................................................................................................................ 2
2. Compliance...................................................................................................................................... 3
2.1 Assumptions ............................................................................................................................ 3
2.2 Product identification.............................................................................................................. 3
2.3 SIL conformity.......................................................................................................................... 3
2.4 Relevant standards.................................................................................................................. 3
3. Safety............................................................................................................................................... 4
3.1 Safety requirements................................................................................................................ 4
3.2 Service Proven ......................................................................................................................... 4
4. Safety-related characteristics.......................................................................................................... 4
4.1 Basics ....................................................................................................................................... 4
4.2 Safe function............................................................................................................................ 5
4.3 Specific characteristics ............................................................................................................ 5
4.4 Time-dependent process of PFDavg.......................................................................................... 5
4.5 Service life ............................................................................................................................... 5

Functional safety manual –Series 8000 and Hydrobar
SM-EN-8000/09-2013/01 Page 2
1. Functional Safety
1.1 Scope
This safety manual applies to measuring systems consisting of Klay Instruments pressure transmitter in a
two wire 4-20 mA loop.
This functionally safety manual applies for:
Series 8000, 8000-SAN, CER-8000, 8000-SAN Cable, Hydrobar Cable and Hydrobar Cable-FR.
With a serial number of the transmitter > 10509426
1.2 Application area
The measuring system can be used for process pressure or level measurement of gases, vapours and liquids
which meet the specific requirements of the safety technology.
1.3 Safety function
The device generates an analogue output signal of 4-20 mA that is proportional to the current pressure.
This has to be controlled by a downstream logical unit (e.g. PLC). For the malfunction detection, the logical
unit has to distinguish between 4-20 mA-signals and the fault current < 3.3 mA or > 20.8 mA. Observe with
the conception of the system, that the technical data of the product-specific as well as Functional Safety
Data Sheet may not be exceeded. Especially the permissible operating condition (permissible temperatures,
etc.) have to be ensured.
Make sure that the entire interconnection of different components fulfills the requirements of the
application. The operator is responsible for correct construction of the overall system.
After installation a validation of the safety function is required.
The installation, maintenance and cleaning of the devices must be performed exclusively by persons
specifically trained and authorized for this purpose as far as they are familiar with the devices!
The operability of the measuring device should be checked via proof test in regularly intervals. For
defining the scope and interval of tests, the following table can be used as a reference. However
each application has its own unique properties and exceptions. Klay Instruments is not an expert in
the customer’s process (technical field) and does not accept liability for consequential damage of
any kind due to use or misuse of the Series 8000 and Hydrobar.
Industry
Application
Frequency of proof test
Twice a year
Yearly
Every two years
Food and Dairy
Fluids
●
Steam and Air
●
Homogenisors
●
Brewery and Beverage
Fluids
●
Steam and Air
●
Homogenisors
●
Pharmaceutical
Fluids
●
Steam and Air
●
Pulp and Paper
Fluids
●
Steam and Air
●
Industry
Application
Frequency of proof test
Twice a year
Yearly
Every two years
Shipbuilding and Marine
Fluids
●
Steam and Air
●
Water and Wasted Water
Fluids
●
Air
●
Chemical and Petrochemical
Fluids
●
Steam, Air and Gasses
●
Oil and Gas
Fluids
●
Steam, Air and Gasses
●
Drilling systems
●
Others (Machinebuilding)
Fluids
●
Steam, Air and Gasses
●

Functional safety manual –Series 8000 and Hydrobar
SM-EN-8000/09-2013/01 Page 3
Modifications on devices and connections void Functional Safety and the warranty!
It is the responsibility of the user to verify whether the chosen version of the device is suitable for
the intended application and the existing environmental conditions. Klay Instruments does not
assume any liability for an incorrect selection and its consequences.
2. Compliance
2.1 Assumptions
The average ambient temperature during the operating time is 20°C - 40 °C (68 °C - 104 °F).
The environmental conditions correspond to an industrial environment.
The lifetime of the components is around 10 to 14 years (IEC 61508-2, 7.4.7.4, remark 3).
2.2 Product identification
Make sure the device has been ordered with SIL-conformity and has been delivered conformably.
The transmitter is clearly marked with a special SIL marking on the enclosure.
2.3 SIL conformity
The SIL conformity is confirmed by the verification documents in the appendix.
Series 8000 and Hydrobar
IEC 61508:2010
Type A
FT0
SIL2
SC2
IEC 61511:2003
Type A
FT1
SIL3
Abbreviations, terms
SIL
Safety Integrity Level
HFT
Hardware Fault Tolerance
SFF
Safe Failure Fraction
PFDAVG
Average Probability of dangerous Failure on Demand
PFH
Probability of a dangerous Failure per Hour
FMEDA
Failure Mode, Effects and Diagnostics Analysis
λsd
Rate for safe detected failure
λsu
Rate for safe undetected failure
λdd
Rate for dangerous detected failure
λdu
Rate for dangerous undetected failure
DCS
Diagnostic Coverage of safe failures; DCS= λsd/(λsd+λsu)
DCD
Diagnostic Coverage of dangerous failures; DCD= λdd/(λdd+λdu)
FIT
Failure In Time (1 FIT = 1 failure/109h)
MTBF
Mean Time Between Failure
MTTF
Mean Time To Failure
MTTR
Mean Time To Repair
Further abbreviations and terms are stated in IEC 61508-4.
2.4 Relevant standards
IEC 61508:2010
Functional safety of electrical/electronic/programmable electronic safety-related systems
IEC 61511-1:2003
Functional safety - safety instrumented systems for the process industry sector - Part 1:
Framework, definitions, system, hardware and software requirements

Functional safety manual –Series 8000 and Hydrobar
SM-EN-8000/09-2013/01 Page 4
3. Safety
3.1 Safety requirements
Failure limit values for a safety function, depending on the SIL class (of IEC 61508-1, 7.6.2)
Safety integrity level
Low demand mode
SIL
PFDavg
4
≥ 10-5 … < 10-4
3
≥ 10-4 … < 10-3
2
≥ 10-3 … < 10-2
1
≥ 10-2 … < 10-1
Safety integrity of hardware for safety-related subsystems of type A (IEC 61508-2, 7.4.3)
Safe failure fraction
Hardware fault tolerance
SFB
HFT = 0
HFT = 1 (0)
HFT = 2
< 60 %
SIL1
SIL2
SIL3
60 % … < 90 %
SIL2
SIL3
SIL4
90 % … < 99 %
SIL3
SIL4
SIL4
≥ 99 %
SIL3
SIL4
SIL4
3.2 Service Proven
According to IEC 61511-1, paragraph 11.4.4, the failure tolerance HFT can be reduced by one for
service-proven subsystems if the following conditions are met:
The hardware of the device is selected on the basis of prior use (see IEC 61511-1 Cl. 11.5.3)
The device allows adjustment of process-related parameters only, for example, measuring
range, upscale or downscale failure direction.
The adjustment of the process-related parameters of the device is protected.
The function has a SIL requirement of less than 4.
SIL
Minimum hardware fault tolerance
(see 11.4.3 and 11.4.4)
1
0
2
1
3
2
4
Special requirements apply (see IEC 61508)
The user must have experience with this process, and must be in compliance by the requirements of
IEC 61511-1 clause 11.5.3. The operating experience must be recorded in the user’s list of equipment
approved for use in their facilities.
4. Safety-related characteristics
4.1 Basics
The failure rates of the electronics, the mechanical parts of the transmitter as well as the process
fitting are determined by an FMEDA according to IEC 61508. The calculations are based on
component failure rates according to SN 29500. All values refer to an average ambient temperature
during the operating time of 55 °C (104 °F). For a higher average temperature of 60 °C (140 °F), the
failure rates should be multiplied by a factor of 2.5. A similar factor applies if frequent temperature
fluctuations are expected.

Functional safety manual –Series 8000 and Hydrobar
SM-EN-8000/09-2013/01 Page 5
4.2 Safe function
A measurement of absolute and relative pressure or level within the specified safety
accuracy of 0.2 % from full span.
The safety function response time is 50ms.
4.3 Specific characteristics
Failure Rate
Type of rating
Failure in time (FIT)
λsd (safe detected failure)
0.00
λsu (Safe undetected failure)
104.14
λdd (Dangerous detected failure)
0.00
λdu (Dangerous undetected failure)
36.38
Single channel architecture (1oo1D)
SIL
SIL2
HFT
0
Instrument type
A
SFF
74 %
PFDavg
TProof = 1 Year
TProof = 2 years
TProof = 5 years
TProof = 10 years
TProof = 15 years
< 0.161 x 10-3
< 0.321 x 10-3
< 0.799 x 10-3
< 0.159 x 10-2
< 0.239 x 10-2
4.4 Time-dependent process of PFDavg
The chronological sequence of PFDavg is nearly linear to the operating time over a period up to 10
years. The above values apply only to the TProof interval after which a recurring function test must
be carried out
4.5 Service life
After 10 to 14 years, the failure rates of the electronic components will increase, whereby the
derived PFD values will deteriorate (IEC 61508-2, 7.4.7.4, note 3).