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
07/2010, A5E00729184-02
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

Siemens AG
SIL Safety Manual CALOMAT 6 Gas Analyzers 4
A5E00729184-02, 07/2010
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

Siemens AG
5Safety Manual CALOMAT 6 Gas Analyzers
07/2010, A5E00729184-02
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”.

Siemens AG
SIL Safety Manual CALOMAT 6 Gas Analyzers 6
A5E00729184-02, 07/2010
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.

Siemens AG
7Safety Manual CALOMAT 6 Gas Analyzers
07/2010, A5E00729184-02
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.

Siemens AG
SIL Safety Manual CALOMAT 6 Gas Analyzers 8
A5E00729184-02, 07/2010
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

Siemens AG
9Safety Manual CALOMAT 6 Gas Analyzers
07/2010, A5E00729184-02
3
Device-specific safety instructions
3.1 Applications
The Hardware assessment of the CALOMAT 6 shall provide the safety
instrumentation engineer with the required failure data as per IEC 61508 / IEC
61511 and does not include an assessment of software.
The hardware of CALOMAT 6 satisfies the special requirements in terms of
functional safety to SIL 1 in accordance with IEC 61508 or IEC 61511-1.
The CALOMAT 6 is usable in safety applications to monitor limits.
3.2 Safety function
The CALOMAT 6 is mainly used for user defined threshold monitoring. Only the
analog output 4.20 mA (NAMUR) was calculated as safety function. The danger-
ous failure is a deviation of the output current of ±5% full span.
Warning
The binding settings and conditions are listed in the “Settings” and “Safety
characteristics” sections. These conditions must be met in order to fulfil the
safety function.
When the safety function has been executed, safety-instrumented systems with
no self locking function should be brought to a monitored or otherwise safe
status within the Mean Time To Repair (MTTR). The MTTR is 8 hours.
The calculated Mean Time Between Failure (MTBF) for CALOMAT 6 is 78 years.
Reference
Instruction manual CALOMAT 6E/F (Order number see chapter 1.3)
See also
Settings (Chapter 3-3)
Safety characteristics (Chapter 3-6)

Siemens AG
SIL Safety Manual CALOMAT 6 Gas Analyzers 10
A5E00729184-02, 07/2010
3.3 Settings
After assembly and commissioning in line with the device manual, the following
parameter settings should be made for the safety function:
Safety parameters
Please enter following parameter via CALOMAT 6 menu:
Function
Number
Function
70 Analog Output Select 4..20 mA (Namur)
Reference
Instruction Manual CALOMAT 6E/F
Protection against configuration changes
After configuration, the CALOMAT 6 access codes (function number 79) shall be
changed so that the device is protected against unwanted and unauthorized
changes/operation.
Checking the safety function after installation
After installation of the CALOMAT 6 a safety function test has to be carried out
(see chapter 4 “Maintenance“ and 5 “Operation“ of the instruction manual
CALOMAT 6E/F).
Using zerogas, i.e. N2, 4 mA must be measured at the analog output.
For the test of the safety function it is fundamental to use a second reference gas
with a defined proportion of component to be measured. The results of the
measurement must be within a range of ±5% (full span) of the expected result.

Siemens AG
11 Safety Manual CALOMAT 6 Gas Analyzers
07/2010, A5E00729184-02
3.4 Behavior in case of faults
Fault
The procedure in case of faults is described in the device operating manual /1/.
Repairs
Defective devices should be sent to the Repair Department with details of the
fault and the cause. When ordering replacement devices, please specify the serial
number of the original device. The serial number can be found on the
nameplate.
Reference
The address of the responsible repair center, contact, spare parts lists etc. can be
found in the Instruction Manual CALOMAT 6E/F at chapter 8.2 (”return delivery”).
Or look at following web addresses:
www.siemens.com/automation/services&support
www.automation.siemens.com/partner
3.5 Maintenance / Checking
Checking
function
We recommend that the functioning of the CALOMAT 6 is checked at regular
intervals of one year.
Check at least the following:
Test the basic functionality of the CALOMAT 6 as described in the Instruction
Manual /1/.

Siemens AG
SIL Safety Manual CALOMAT 6 Gas Analyzers 12
A5E00729184-02, 07/2010
Checking safety
You should regularly check the safety function of the entire safety circuit in line
with IEC 61508/61511.
The testing intervals are determined during circulation of each individual safety
circuit in a system (PFDAVG). Recommended prove interval depends on application
but max within one year. We recommend a prove test interval of once per moth.
To detect dangerous undetected faults the CALOMAT 6 analog output shall be
checked with following test:
To execute the safety proof test both tests (1 and 2) must be performed.
Proof test 1 consists of the steps described in table 3-1.
Step Action
1 Bypass the safety PLC or take other appropriate action to avoid a false
trip
2 Generate or simulate an alarm condition to force the Gas Analyzer
CALOMAT 6 to go to the high alarm current output and verify that the
analog current reaches that value.
3 Generate or simulate an alarm condition to force the Gas Analyzer
CALOMAT 6 to go to the low alarm current output and verify that the
analog current reaches that value.
4 Restore the loop to full operation
5 Remove the bypass from the safety PLC or otherwise restore normal
operation
Table 3-1 Steps for Proof Test 1
Proof test 2 consists of the steps described in Table 3-2.
Step Action
1 Bypass the safety PLC or take other appropriate action to avoid a false
trip
2 Perform Proof Test 1
3 Perform a two-point calibration of the Gas Analyzer CALOMAT 6
4 Perform a reference measuring with at least one measuring point
between min and max concentration. You must use a calibration gas
with a well known gas concentration. The expected result must have a
tolerance of not more than 5 %.
5 Restore the loop to full operation
6 Remove the bypass from the safety PLC or otherwise restore normal
operation
Table 3-2 Steps for Proof Test 2
This test will detect more than 90% of possible "du" failures in the Gas Analyzer
CALOMAT 6.

Siemens AG
13 Safety Manual CALOMAT 6 Gas Analyzers
07/2010, A5E00729184-02
3.6 Safety characteristics
The safety characteristics necessary for use of the system are listed in the SIL
declaration of conformity (see chapter Appendix). These values apply under the
following conditions:
The CALOMAT 6 is only used in safety-related systems with a low demand
mode for the safety function.
The safety-related parameters/settings (see “Settings” section) have been
entered by local operation and checked before commencing safety-
instrumented operation.
The CALOMAT 6 is blocked against unwanted and unauthorized changes/
operation.
The average temperature viewed over a long period is 40°C.
All used materials are compatible with process conditions.
The MTTR after a device fault is 8 hours.
The best time to react on a dangerous detected failure is 1 hour.
The logic solver (PLC) has to be configured to detect over range (>21mA)
and under range (<3.6mA) failure of the CALOMAT 6 (Fail High and Fail
Low) and will recognize these as internal failure of the devices and not
cause a spurious trip.
See also
Settings (Chapter 3-3)
SIL Declaration of Conformity (Chapter A.1)

Siemens AG
SIL Safety Manual CALOMAT 6 Gas Analyzers 14
A5E00729184-02, 07/2010
A
Appendix
A.1 SIL Declaration of Conformity

Siemens AG
15 Safety Manual CALOMAT 6 Gas Analyzers
07/2010, A5E00729184-02
A.2 exida Test Report (extract)

Siemens AG
SIL Safety Manual CALOMAT 6 Gas Analyzers 16
A5E00729184-02, 07/2010

Siemens AG
17 Safety Manual CALOMAT 6 Gas Analyzers
07/2010, A5E00729184-02
B
List of Abbreviations/Acronyms
B.1 Abbreviations
Abbreviation Full term in English Meaning
FIT Failure in Time Frequency of failure of the protective function
HFT Hardware Fault Tolerance Hardware fault tolerance: Capability of a func-
tion unit to continue executing a required func-
tion in the presence of faults or deviations.
MTBF Mean Time Between Failures Average period between two failures
MTTR Mean Time To Repair Average period between the occurrence of a
fault on a device or system and the repair
PFD Probability of Failure on Demand Probability of dangerous failures of a safety
function on demand
PFDAVG Average Probability of Failure on Demand Average probability of dangerous failures of a
safety function on demand
PLC Programmable Logic Controller
SIL Safety Integrity Level The international standard IEC 61508 defines
four discrete Safety Integrity Levels (SIL 1 to
SIL 4). Each level corresponds to a range of
probability for failure of a safety function. The
higher the Safety Integrity Level of the safety-
instrumented system, the lower the probability
that it will not execute the required safety func-
tions.
SFF Safe Failure Function Proportion of safe failures: Proportion of failures
without the potential to bring the safety instru-
mented system into a dangerous on no permis-
sible functional status.
TI Test Interval Testing interval of the protective function
XooY "X out of Y" voting Classification and description of the safety-
instrumented system in terms of redundancy
and the selection procedures used.
"Y" -Specifies how often the safety function is
executed (redundancy).
"X" -Determines how many channels have to
work correctly.
Example:
Pressure measurement: 1oo2 architecture. A
safety instrumented system decides that a
specified pressure limit has been exceeded if
one out of two pressure sensors reaches this
limit. In a 1oo1 architecture, there is only one
pressure sensor.

Siemens AG
SIL Safety Manual CALOMAT 6 Gas Analyzers 18
A5E00729184-02, 07/2010
Glossary
Dangerous failure
Failure with the potential to bring the safety-instrumented system into a
dangerous or non-functional status
Low Demand Mode
The frequency of demands for operation made on a safety related system is no
greater than one per year and no greater than twice the proof-test frequency;
Safety function
Defined function executed by a safety-instrumented system with the objective of
achieving or maintaining a safe system status taking into account a defined
dangerous occurrence.
Example:
Monitoring of user defined threshold values.
Safety Integrity Level
SIL
Safety-instrumented system
A safety-instrumented system excludes 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 a pressure transmitter, a limit signal
sensor and a control valve.
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 of 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)