Masoneilan Svi ii esd Manual

Masoneilan*

SVI*II ESD

Smart Valve Interface with SIL3

Emergency Shutdown PST Controller

Installation and Maintenance Manual (Rev. G)

BHGE Data Classification: Public

About this Guide

This instruction manual covers the following instruments and approved software:

Through SVI II ESD -6

with Firmware version 3.1.2 or greater

with ValVue* ESD version 1.0 or greater

with Handheld HART®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

The information contained in this manual, in whole or part, shall not be transcribed or copied without BHGE’s written per-

mission.

In no case does this manual guarantee the merchantability of the positioner or the software or its adaptability 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.

U. S. Patent No. 6,957,127, Additional Patents Pending

DISCLAIMER

THESE INSTRUCTIONS PROVIDE THE CUSTOMER/OPERATOR WITH IMPORTANT PROJECT-SPECIFIC REFERENCE

INFORMATION IN ADDITION TO THE CUSTOMER/OPERATOR’S NORMAL OPERATION AND MAINTENANCE 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, OPERATION OR MAINTENANCE.

SHOULD FURTHER INFORMATION BE DESIRED OR SHOULD PARTICULAR PROBLEMS 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 EQUIPMENT. 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 INSTALLATION,

TESTING, OPERATION, AND/OR MAINTENANCE OF THE EQUIPMENT DESCRIBED. THIS DOCUMENT SHALL NOT BE

REPRODUCED IN WHOLE OR IN PART TO ANY THIRD PARTY WITHOUT THE WRITTEN APPROVAL OF BHGE.

All information contained herein is believed to be accurate at the time of publication and is subject to change

without notice.

PN 011523-561 Rev. G

Masoneilan SVI II ESD Installation and Maintenance Manual =|3

Document Changes

Version/Date Changes

B/04-2011 Removed non-installation software-related issues (See help). Rearranged book. Updated installation.

Amended Switches description.

Registration section updated to GE logo software.

C/03-2013 Removed references to double-acting.

D/09-2013 Changed the Simplified Switch diagram in Output Switches section and added a cross reference to it

in the install section. Added Cautions about Position Low and Upper Limits.

Added text about the 4-20 retransmit galvanic isolation.

E/02-2014 Updated load description for optional switches.

F/04-2016 Updated the Installation section and the Fault Matrix.

Modified connection drawings for intrinsically safe in Appendices B and C.

Made changes to Wiring Guidelines for Position retransmit.

G/08-2017 Added How Do I section.

Added Determining Compliance Voltage section.

Added Troubleshooting Autotune section.

Added Notes on Aggressiveness section.

Added DD Navigation section.

Modified Burst Mode section.

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Contents

1. Safety Information ........................................................................................................................................................................17

Introduction ...................................................................................................................................................................................17

Terms and Abbreviations.........................................................................................................................................................17

Acronyms................................................................................................................................................................................18

Safety Symbols.............................................................................................................................................................................19

Related Literature .......................................................................................................................................................................19

Reference Standards.................................................................................................................................................................20

SVI II ESD Device Description.................................................................................................................................................20

Designing an SIF Using an SVI II ESD .................................................................................................................................21

Safety Function....................................................................................................................................................................21

Environmental Limits.........................................................................................................................................................21

Design Verification .............................................................................................................................................................22

SIL Capability.........................................................................................................................................................................22

Connecting the SVI II ESD to the SIS Logic Solver................................................................................................23

General Requirements......................................................................................................................................................24

Installation......................................................................................................................................................................................25

SVI II ESD Installation Configurations ........................................................................................................................25

Physical Location and Placement Guidelines........................................................................................................25

Pneumatic Connections...................................................................................................................................................25

Electrical Connections ......................................................................................................................................................25

Operation, Setup, Commissioning.......................................................................................................................................25

Maintenance..................................................................................................................................................................................25

Diagnostics.....................................................................................................................................................................................25

PST..............................................................................................................................................................................................25

SVI II ESD Product Safety .........................................................................................................................................................27

2. Introduction ......................................................................................................................................................................................29

ValVue ESD Overview ................................................................................................................................................................29

ValVue ESD Software.................................................................................................................................................................30

ValVue ESD Trial Version..................................................................................................................................................30

System Requirements.......................................................................................................................................................31

Available Models..................................................................................................................................................................32

About This Manual ......................................................................................................................................................................32

6 | BHGE

3. Software Installation and Setup .............................................................................................................................................33

Install ValVue ESD and PRM Plug-In....................................................................................................................................33

Installing ValVue ESD Software.....................................................................................................................................33

Installing the Yokogawa® PRM Plug-In ....................................................................................................................37

Registering ValVue ESD.............................................................................................................................................................49

Entering Software Keys ....................................................................................................................................................53

How Do I? ........................................................................................................................................................................................55

4. Installation and Setup ..................................................................................................................................................................57

Overview ..........................................................................................................................................................................................57

SVI II ESD Dimensions and Weights............................................................................................................................58

Pre-Installation Issues ...............................................................................................................................................................59

Storage.....................................................................................................................................................................................59

Unpacking...............................................................................................................................................................................59

Installation ......................................................................................................................................................................................59

Physical Location and Placement Guidelines ........................................................................................................60

Mounting the SVI II ESD on Rotary Valves................................................................................................................63

Travel Sensor Alignment ..................................................................................................................................................65

Mounting the SVI II ESD with NAMUR Kits................................................................................................................66

Mounting the SVI II ESD on Reciprocating Valves ................................................................................................68

Checking the Magnet ........................................................................................................................................................71

Using ValVue ESD to Check Magnet Position .........................................................................................................71

Checking Actuator, Linkages, or Rotary Adapter .................................................................................................72

Connecting the Tubing and Air Supply......................................................................................................................73

Checking the Air Supply....................................................................................................................................................75

Wiring the SVI II ESD...........................................................................................................................................................75

Powering Up the SVI II ESD .............................................................................................................................................80

Making Connections to the Terminal Board ...........................................................................................................85

SVI II ESD Maintenance .............................................................................................................................................................86

Repair and Replacement .................................................................................................................................................86

Factory Notification............................................................................................................................................................86

Display Cover Removal and Installation...................................................................................................................87

5. Configuration and Calibration .................................................................................................................................................89

Overview.........................................................................................................................................................................................89

SVI II ESD Setup.............................................................................................................................................................................89

Configuration.................................................................................................................................................................................90

Configuration with Pushbutton Display ............................................................................................................................90

Calibration with Pushbutton Display..................................................................................................................................93

Calibration using Auto Tune...........................................................................................................................................94

Correct for Over Travel......................................................................................................................................................96

Adjust Input Signal Range ...............................................................................................................................................96

Configuring with ValVue ESD .................................................................................................................................................97

Starting ValVue ESD/ESDVue .........................................................................................................................................97

Check-out with a HART® Handheld Communicator ..................................................................................................98

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6. Using the Digital Interfaces .................................................................................................................................................... 101

Overview....................................................................................................................................................................................... 101

Local Display and Pushbuttons ................................................................................................................................. 101

HART® Handheld Communicator ............................................................................................................................ 102

ValVue ESD .......................................................................................................................................................................... 102

Pushbuttons and Local Display ......................................................................................................................................... 103

Accessing Pushbuttons ................................................................................................................................................. 105

Pushbutton Locks and Configuration-Lock Jumper........................................................................................ 105

Display Menus............................................................................................................................................................................ 107

NORMAL Operating Mode and MANUAL Mode Menus................................................................................... 107

Configure Menu................................................................................................................................................................. 108

Calibration Menu .............................................................................................................................................................. 110

PST Configuration Menu ............................................................................................................................................... 111

VIEW DATA Menu.............................................................................................................................................................. 112

PST CONF (VIEW DATA) Menu ..................................................................................................................................... 114

VIEW ERR.............................................................................................................................................................................. 115

Clear Error.................................................................................................................................................................................... 116

FAILSAFE Mode.................................................................................................................................................................. 116

Handheld Communicator..................................................................................................................................................... 117

ValVue ESD .................................................................................................................................................................................. 118

DD Navigation............................................................................................................................................................................ 119

7. Partial Stroke Testing ................................................................................................................................................................ 121

Overview....................................................................................................................................................................................... 121

Partial Stroke Test Diagnostics .......................................................................................................................................... 122

PST Configuration..................................................................................................................................................................... 122

PST Configuration with Display Menu..................................................................................................................... 122

PST Setup with ValVue ESD.................................................................................................................................................. 124

PST Data from ESDVue .................................................................................................................................................. 124

8. Operation and Maintenance ................................................................................................................................................. 127

Operational Overview............................................................................................................................................................. 127

SVI II ESD Applications and Designated Safety Function Activation........................................................ 128

Additional Features ......................................................................................................................................................... 129

Physical and Operational Description ............................................................................................................................ 130

SVI II ESD Components........................................................................................................................................................... 131

Electronics Module .......................................................................................................................................................... 131

Output Switches................................................................................................................................................................ 133

Pneumatic Module........................................................................................................................................................... 136

Optional Display and Pushbuttons .......................................................................................................................... 137

SVI II ESD Maintenance.......................................................................................................................................................... 137

Repair and Replacement.............................................................................................................................................. 137

Factory Notification......................................................................................................................................................... 138

Display Cover Removal and Installation................................................................................................................ 138

Upgrading Firmware............................................................................................................................................................... 140

Tools Required ................................................................................................................................................................... 140

Installing Firmware Upgrade...................................................................................................................................... 140

8 | BHGE

9. Troubleshooting ...........................................................................................................................................................................141

Overview .......................................................................................................................................................................................141

Internal Diagnostics.................................................................................................................................................................141

FAILSAFE Mode .................................................................................................................................................................142

Accessing Diagnostic Information....................................................................................................................................142

Error Messages on LCD..........................................................................................................................................................143

Positioner Fault Messages ...........................................................................................................................................143

Return to Normal Operation........................................................................................................................................143

VIEW ERR Diagnostics Messages..............................................................................................................................144

Fault Matrix..................................................................................................................................................................................145

Troubleshooting with ESDVue ............................................................................................................................................159

Appendix A. Specifications and References ........................................................................................................................161

Physical and Operational Specifications .......................................................................................................................161

Models and Applications .......................................................................................................................................................167

Hazardous Area Certifications ...................................................................................................................................167

SVI II ESD Models...............................................................................................................................................................170

Appendix B. Installing an SVI II ESD in a Natural Gas Environment .........................................................................171

Remote Actuator Vent Gas Connection.........................................................................................................................173

Remote Gas Piping...........................................................................................................................................................173

Single Acting Installation...............................................................................................................................................173

Appendix C. HART® Wiring Configurations .........................................................................................................................175

Overview .......................................................................................................................................................................................175

System Connections................................................................................................................................................................175

HART® Wiring Guidelines .....................................................................................................................................................177

SVI II ESD Setups ...............................................................................................................................................................178

Grounding Practices........................................................................................................................................................180

Compliance Voltage in Single Drop Current Mode ...........................................................................................181

Wire Size and Conduit ....................................................................................................................................................182

HART® Physical Layer Compliance of the Control System...................................................................................183

Impedance Constraints .................................................................................................................................................183

Noise Constraints .............................................................................................................................................................183

Cabling and Interconnection Requirements........................................................................................................184

Capacitance vs. Length of Cable for HART®.......................................................................................................184

HART® Filter Required for Certain Control System Output Circuits .........................................................184

Split Range Applications........................................................................................................................................................185

Setting Loop Addresses for Split Range Systems..............................................................................................185

Multiple Output Circuit Control System..................................................................................................................187

Isolators ................................................................................................................................................................................188

Supplemental Power Supply .......................................................................................................................................190

Verify Wiring and Connections...................................................................................................................................190

Required Practices for Explosion Proof Installations ...............................................................................................192

Clarification of Terminology ........................................................................................................................................192

Recommended Practice for Severe or Humid Environments......................................................................192

Masoneilan SVI II ESD Installation and Maintenance Manual =|9

HART® DCV Setup.................................................................................................................................................................... 193

HART® Module Positions.............................................................................................................................................. 193

Field Wiring ......................................................................................................................................................................... 193

Appendix D. HART® Communications with Intrinsic Safety ........................................................................................ 195

Overview....................................................................................................................................................................................... 195

HART® Barrier Compliance ................................................................................................................................................. 196

Output Channel Isolation...................................................................................................................................................... 197

HART® Filter Requirements................................................................................................................................................. 197

Modem and Computer Use in Intrinsically Safe Circuits........................................................................................ 199

MACTek® Intrinsically Safe modem, Model 010005........................................................................................ 199

MACTek® Warning ......................................................................................................................................................... 199

Use of Hand-held Communicators In Intrinsically Safe Circuits ................................................................ 199

Appendix E. Air to Open and Air to Close Actuators ........................................................................................................ 201

Actuator Action.......................................................................................................................................................................... 201

Appendix F. Air Supply Requirements .................................................................................................................................... 205

Appendix G. Adjusting Speed of Response .......................................................................................................................... 207

Appendix H. Glossary ..................................................................................................................................................................... 209

Appendix I. Determining an SVI Positioner Compliance Voltage in a Control System .................................... 217

Compliance Test Setup.......................................................................................................................................................... 217

Appendix J. Burst Mode Operations ....................................................................................................................................... 219