Siemens CALOMAT 6 User manual

Supplement to instruction manual
CALOMAT 6
CALOMAT 6F
7MB2511, 7MB2517
CALOMAT 6E
7MB2521, 7MB2527
Ordering Number: A5E00729184
07/2010
CALOMAT 6
Thermal Conductivity
Gas Analyzers
SIL Safety Manual

Siemens AG
SIL Safety Manual CALOMAT 6 Gas Analyzers 2
A5E00729184-02, 07/2010
Safety Guidelines
This manual contains notices you have to observe in order to ensure your personal safety, as well as to
prevent damage to property. The notices referring to your personal safety are highlighted in the manual
by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These
notices shown below are graded according to the degree of danger.
Danger
indicates that death or severe personal injury will result if proper precautions are not taken.
Warning
indicates that death or severe personal injury may result if proper precautions are not taken.
Caution
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
Caution
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
Notice
indicates that an unintended result or situation can occur if the corresponding information is not taken into ac-
count.
If more than one degree of danger is present, the warning notice representing the highest degree of
danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a
warning relating to property damage.
Qualified Personnel
The device/system may only be set up and used in conjunction with this documentation. Commissioning
and operation of a device/system may only be performed by qualified personnel. Within the context of
the safety notes in this documentation qualified persons are defined as persons who are authorized to
commission, ground and label devices, systems and circuits in accordance with established safety prac-
tices and standards.
Prescribed Usage
Note the following:
Warning
This device may only be used for the applications described in the catalog or the technical description and only in
connection with devices or components from other manufacturers which have been approved or recommended by
Siemens. Correct, reliable operation of the product requires proper transport, storage, positioning and assembly
as well as careful operation and maintenance.
Trademarks
All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in
this publication may be trademarks whose use by third parties for their own purposes could violate the
rights of the owner.
Disclaimer of liability
While we have verified the contents of this manual for agreement with the hardware and software de-
scribed, variations remain possible. Thus we cannot guarantee full agreement. The contents of this
manual are regularly reviewed and corrections are included in subsequent editions. We welcome all
suggestions for improvement.
Copyright © SIEMENS AG 2005
Subject to change without further notice

Siemens AG
3Safety Manual CALOMAT 6 Gas Analyzers
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Table of contents
Introduction ..................................................................................................................4
1.1 General ................................................................................................................. 4
1.2 Purpose of this document....................................................................................... 4
1.3 Required documentation ........................................................................................ 4
1.4 Change history....................................................................................................... 5
1.5 Further information ............................................................................................... 5
General Safety Instructions ..........................................................................................6
2.1 Safety-instrumented system ................................................................................... 6
2.2 Safety Integrity Level (SIL) ...................................................................................... 8
Device-specific safety instructions ...............................................................................9
3.1 Applications........................................................................................................... 9
3.2 Safety function ...................................................................................................... 9
3.3 Settings............................................................................................................... 10
3.4 Behavior in case of faults...................................................................................... 11
3.5 Maintenance / Checking ....................................................................................... 11
3.6 Safety characteristics............................................................................................ 13
Appendix .....................................................................................................................14
A.1 SIL Declaration of Conformity ..........................................................................14
A.2 exida Test Report (extract)...............................................................................15
List of Abbreviations/Acronyms ..................................................................................17
B.1 Abbreviations ...................................................................................................17
Glossary.......................................................................................................................18

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SIL Safety Manual CALOMAT 6 Gas Analyzers 4
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1
Introduction
1.1 General
The following table lists all available CALOMAT 6 types:
Analyzer name Standard
analyzer
Special
analyzer
CALOMAT 6F 7MB2511 7MB2517
CALOMAT 6E 7MB2521 7MB2527
1.2 Purpose of this document
This document contains information and safety instructions that you will require
when using the CALOMAT 6 in safety-instrumented systems.
It is aimed at system planners, constructors, service and maintenance engineers
and personnel who will commission the device.
1.3 Required documentation
This document deals with the CALOMAT 6 gas analyzer exclusively as part of a
safety function. This document only applies in conjunction with the following
documentation:
No. Name Order No.
/1/ INSTRUCTION MANUAL:
Thermal Conductivity
Gas Analyzer
A5E00116454 (German)
A5E00116455 (English)
A5E00116456 (French)
A5E00116457 (Spanish)
A5E00116458 (Italian)
INSTRUCTION MANUAL:
Application: “Turbogenerator-
Überwachung”
A5E00185981

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1.4 Change history
Currently released versions of this documentation:
Edition Comment
04/2006 First edition (A5E00729184-01)
07/2010 Second edition: Declaration of conformity updated
1.5 Further information
Information
The contents of these instructions shall not become part of or modify any prior or
existing agreement, commitment or legal relationship. All obligations on the part
of Siemens AG are contained in the respective sales contract which also contains
the complete and solely applicable warranty conditions. Any statements
contained herein do not create new warranties or modify the existing warranty.
The content reflects the technical status at the time of printing. We reserve the
right to make technical changes in the course of further development.
References
If there are references to further information on an aspect described here, these
will always be found at the end of a chapter under “See also”.

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2
General Safety Instructions
2.1 Safety-instrumented system
Definition: Safety-instrumented system
A safety instrumented system executes the safety functions that are required to
achieve or maintain a safe status in a system. It consists of a sensor, logic unit/
control system and final controlling element.
Example:
A safety instrumented system is made up of an analyzer (for example H2
concentration), a PLC and a control valve (Figure 2-1).
Definition: Safety function
Defined function executed by a safety instrumented system with the objective of
achieving or maintaining a safe system taking into account a defined dangerous
occurrence.
Example:
O2-concentration
Definition: Dangerous failure
Failure with the potential to bring the safety instrumented system into a
dangerous or non-functional status.
Description
The analyzer logic unit/control system is a final controlling element combine to
form a safety-instrumented system, which executes a safety function.
Note This document deals with the CALOMAT 6 exclusively as part of a safety function.

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7Safety Manual CALOMAT 6 Gas Analyzers
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Control System
Figure 2-1 Example of a safety-instrumented system
Function
The measuring principle is based on the different thermal conductivity of gases.
The CALOMAT 6 operates with a micro-mechanically manufactured Si chip whose
measuring diaphragm contains thin-film resistors.
The resistors are regulated at a constant temperature. A current is required to
achieve this, and its magnitude assumes a particular value depending on the
thermal conductivity of the sample gas. This raw value is subject to further elec-
tronic processing and is used to calculate the gas concentration.
To suppress ambient temperature influences, the sensor is located in a thermo-
statically-controlled stainless steel housing.
To prevent flow influences, the sensor is only subject to an indirect flow
Special characteristics
-Four freely-programmable measuring ranges per component, also with sup-
pressed zero
- All measuring ranges linear!
- The isolated analog output is set to 4 to 20 mA (NAMUR)
For safety instrumented systems the relay output is used for diagnostics only.

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2.2 Safety Integrity Level (SIL)
Definition: SIL
The international standard IEC 61508 defines four discrete Safety Integrity Levels
(SIL) from SIL 1 to SIL 4. Each level corresponds to the probability range for the
failure in a safety function. The higher the SIL of the safety-instrumented system,
the higher the probability that the required safety function will work.
The achievable SIL is determined by the following safety characteristics:
Average probability of dangerous failure of a safety function in case of
demand (PFDAVG)
Hardware fault tolerance (HFT)
Safe failure fraction (SFF)
Description
The following table shows the dependency of the SIL on the average
probability of dangerous failures of a safety function of the entire safety-
instrumented system (PFDAVG). The table deals with “Low demand mode”, i.e.
the safety function is required a maximum of once per year on average.
SIL PFDAVG
4 ≥10-5 … < 10-4
3 ≥10-4 … < 10-3
2 ≥10-3 … < 10-2
1 ≥10-2 … < 10-1
Table 2-1 Safety Integrity Level
The “average probability of dangerous failures of the entire safety
instrumented system” (PFDAVG) is normally spilt between the three subsystems
in the following figure.
Figure 2-2 PFD distribution
The following table shows the achievable Safety Integrity Level (SIL) for the
entire safety-instrumented system for type B systems depending on the
proportion of safe failures (SFF) and the hardware fault tolerance (HFT). Type
B systems include sensors and positioners actuators with complex
components, e.g. microprocessors (see also IEC 61508, Section 2).
012
<60% Not allowed SIL1 SIL2
60 to 90% SIL1 SIL2 SIL3
90 to 99% SIL2 SIL3 SIL4
>99% SIL3 SIL4 SIL4
HFT
SFF
Sensor
e.g. Gas
Analyzer
Final control-
ling element
e.g. valve
Control
system or
logic unit
e.g. PLC