MANUAL

Competence in Functional Safety
Functional safety of globe
valves, rotary plug valves, ball valves and butterfly valves

SMART IN FLOW CONTROL.

Competence in Functional Safety
Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves

SAMSON
AIR TORQUE · CERA SYSTEM · KT-ELEKTRONIK · LEUSCHPFEIFFER · RINGO · SAMSOMATIC · STARLINE · VETECFounded in 1907, SAMSON has since become a worldwide
leader in the manufacture of expertly engineered control
valves.
SAMSON has over 50 subsidiaries, amongst them noted
manufacturers of special valves.
With these subsidiaries, SAMSON is represented in over
80 countries to assist its customers on all continents.

2

Competence in Functional Safety
Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves

Table of contents
1 Scope................................................................................................................................................................4
2 Validity of this manual.........................................................................................................................................4
3 Intended use of this manual..................................................................................................................................5
4 General aspects of functional safety.....................................................................................................................6
4.1 Standards, terms and abbreviations..............................................................................................................6
4.2 Determining the safety integrity level.............................................................................................................8
4.3 Hardware fault tolerance.............................................................................................................................95 Intended use of control valves in safety-instrumented systems.................................................................................10
5.1 General control valve requirements............................................................................................................. 12
5.2 Globe valve requirements........................................................................................................................... 13
5.3 Ball valve requirements.............................................................................................................................. 15
5.4 Butterfly valve requirements........................................................................................................................ 16
5.5 Rotary plug valve requirements................................................................................................................... 18
5.6 Proof tests and service life.......................................................................................................................... 18
6 Installation, piping and wiring............................................................................................................................ 19
6.1 Mechanical and pneumatic installation........................................................................................................ 19
6.2 Electrical installation..................................................................................................................................20
6.3 Installation of control valves........................................................................................................................20
7 Applicable device documentation.......................................................................................................................22
8 Appendix 1 – Manufacturer‘s declarations..........................................................................................................22
9 Appendix 2 − Example of a checklist for a final element.......................................................................................30

3

Competence in Functional Safety
Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves

1

Scope

Valves and the associated actuators are used to isolate pipelines in safety-instrumented systems. Alternatively, they canalso be used for pressure relief, i.e. by completely opening valves.

2

Validity of this manualThis manual applies to control valves manufactured by the following companies within SAMSON:SAMSON AGLEUSCH GmbH Industriearmaturen

PFEIFFER Chemie-Armaturenbau GmbHVETEC Ventiltechnik GmbH

Refer
toonthemanufacturer‘sdeclarations in Appendix 1 of this manual for the valve models concerned.
Markings
the control
valve
Markings on the device

The individual versions of the valves can be identified by their nameplates

2 Markings on the control valve

2 Markings on the device

2.1 Valve nameplate

2.1 Actuator nameplate

SAMSON
1…5

1…5

6

8

10

11

12

13

14 15

16

The nameplate is stuck on the diaphragm casing. It includes all details required to identify theactuator:

21
17

18

9
19 20

Fig. 1: Valve nameplate

2 Configuration ID
3 Serial number
4 Actuator area

PED (Pressure Equipment Directive), "Art. 4, Abs. 3"

5 Bench range in bar

ID of the notified body, fluid group, and category

6 Bench range in psi

6Type designation

8

Material

9Year of manufacture

10

Valve size:
DIN: DN · ANSI: NPS · JIS: DN … A/B

10 Permissible supply pressure pmax in bar

11

Pressure rating:
DIN: PN · ANSI: CL · JIS: K

12 Symbol indicating fail‑safe action

12

Order no. with modification index
For after-sales service orders: AA prefix

13

Position in order
For after-sales service orders: configuration ID

14

Flow coefficient:
DIN: KVS · ANSI: CV · JIS: CV

15
16

7 Operating travel in mm
8 Operating range in bar
9 Operating range in psi
11 Permissible supply pressure pmax in psi
Actuator stem extends (FA)Actuator stem retracts (FE)Manual override
14 Connecting thread
15 Diaphragm material

Characteristic:%: equal percentage · Lin: linear · NO/NC: quick opening

16 Date of manufacture

Seat/plug seal:
ME: metal (see section 3.3)
HA: carbide metal
ST: Stellite® facing
KE: ceramic
PT: soft seal with PTFE
PK: soft seal with PEEKSAMSON 3271

Seat code (trim material) · On request

18

Pressure balancing:
DIN: D · ANSI: B · JIS: B

19

Flow divider:
1: St I · 3: St III

20

Country of origin

21

PSA version

12

4

4

Made in Germany

12

5
6

7

							17

15

Var-ID
Serial no.

8

2
3
16

14

10

11

9

Fig. 1: Nameplate

10

EB 8310-7 EN

Example of a nameplate for a Type 3241
Valve with Type 3271 or Type 3277 Pneumatic
Actuator manufactured by SAMSON AG
EB 8015 EN

Competence in Functional Safety
Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves

3

Intended use of this manualThis manual is intended to assist planners and operators during the integration of control valves into a safety loop as
part of the safety function and to enable them to safely operate control valves.
This manual contains information, safety-related data and warnings concerning the functional safety in accordancewith IEC 61508 and concerning the application in the process industry in accordance with IEC­­­ 61511. It does not contain any particular details on other safety requirements, such as explosion protection or electrical safety.
Safety-instrumented systems are to be commissioned and maintained by qualified personnel only. Refer to the corresponding mounting and operating instructions of the valve.

5Competence in Functional Safety
Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves

4

General aspects of functional safety

4.1 Standards, terms and abbreviations

Abbreviation

Designation

Description

SIL

Safety Integrity Level

One of four discrete levels for specifying the safety integrity requirementsof the safety functions to be allocated to the E/E/PE safety-related systems,
where SIL 4 has the highest level of safety integrity and SIL 1 has the lowest.

MTBF

Mean Time Between Failures

Mean time between two failures

MTTR

Mean Time To Restoration

Mean time between the occurrence of a failure in a device or system and its
repair

HFT

Hardware Fault Tolerance

Capability of a functional unit to continue executing the demanded function
in case of faults or deviations.

λ sd

Failure rate for all safe detected
failures

λ su

Failure rate for all safe undetected failures

λ dd

Failure rate for all dangerous detected failures

λ duFailure rate for all dangerous undetected
failures

SFF

Safe Failure Fraction

Fraction of non-hazardous failures, i.e. the fraction of failures without thepotential to set the safety-related system to a dangerous or impermissible
state.

PFDavgAverage Probability of Failure on
DemandAverage likelihood that a dangerous safety function failures occurs on
demand.

TI

Test Interval between life testing of the safetyfunction

Average likelihood that a dangerous safety function failures occurs on
demand.

Low demandmode

Low demand mode of operation

Low demand mode is where the frequency of demands for operation madeon a safety-related system is no greater than one per year and no greaterthan twice the proof test frequency.

6

Competence in Functional Safety
Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves

Abbreviation

Designation

Description

MooN

Voting “M out of N“ (e. g. 2oo3)

Classification and description of the safety-related system regarding redundancy and the selection procedure used.
• “N“ indicates how often the safety function is carried out (redundancy).
• “M“ determines how many channels must work properly.
Example: Pressure measurement in 1oo2 architecture
A safety-instrumented system decides that a specified pressure limit has
been exceeded if one of two pressure sensors reaches this limit. In a 1oo1
architecture, there is only one pressure sensor.

MooND

Voting “M out of N“ with diagnostics

Relevant standards
Norm

Designation

IEC 61508
Parts 1 to 7

Functional safety of electrical/electronic/programmable electronic safety-related systems

IEC 61511
Parts 1 to 3

Functional safety – Safety instrumented systems
for the process industry sector

VDI 2180
Parts 1 to 5

Safeguarding of industrial process plants bymeans of process control engineering

Terms and definitions
Term

Definition

Dangerous failure

Failure with the potential to set the safety-related system to a dangerous or inoperative state.

Safety-related system

A safety-related system carries out the safety functions needed to establish or maintain a safe state,e.g. in a plant.
Example: Pressure measuring instrument, logic unit (e.g. limit switch) and valve form a safety-related system.

Safety function

A defined function carried out by a safety-related system in order to establish or maintain a safe state of
the plant, under consideration of a specified dangerous incident.
Example: Pressure limit monitoring

7

Competence in Functional Safety
Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves

4.2 Determining the safety integrity level
The achievable safety integrity level (SIL) is determined by the following safety-related data:Average probability of failure on demand (PFDavg)
Hardware fault tolerance (HFT)

Safe failure fraction (SFF)

The following table in accordance with IEC 61508 and IEC 61511 shows how the safety integrity level (SIL)
depends on the average probability of failure on demand (PFDavg). It is based on low demand mode ofoperation, i.e. the frequency of demands on a safety-related system is no greater than once per year.
Safety integrity level (SIL)

PFDavg (low demand mode)4≥ 10-5 to < 10-4

3

≥ 10-4 to < 10-3

2

≥ 10-3 to < 10-2

1

≥ 10-2 to < 10-1

PFDavg in low demand mode of operation according to IEC 61508-1, Table 2

The sensor, logic unit and final element form a safety-related system that performs a safety function.

Sensore.g. pressure
measuring instrument

PFDavg≤X%

Logic unit
e.g. PLC≤X%

Final element
e.g. valve≤X%

The average probability of failure on demand (PFDavg = sum of sensor, logic unit and final element failures) must be within
the range of the demanded safety integrity level (SIL) in case of demand as listed in the above table.

8Competence in Functional Safety
Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves

4.3 Hardware fault tolerance
In the process industry, the achievable SIL classes for sensors, final elements and non-programmable logic modules,
such as isolating amplifiers and relays, are restricted in accordance with IEC 61511 as shown in the following table.
Safety integrity level (SIL)

Minimum required hardware failure tolerance (HFT)

1

0

2

1

3

2

4

Special requirements (refer to IEC 61508)

Minimum required hardware failure tolerance (HFT) according to IEC 61511-1, Table 6, for the process industry

The minimum required hardware failure tolerance can be decreased by one if the following requirements are met:
The device is proven in use.

 Take this into account when selecting devices!

The device only allows process-relevant parameters to be set, e.g. measuring range, upscale or downscale function

in case of failure.

 Final elements do not have any configurable functions.

The process-relevant parameters of the device are access-protected, e.g. by jumper or password.

 Final elements do not have any configurable functions.

The function requires a SIL less than 4.

A final element has a single-channel design, resulting in a hardware failure tolerance (HFT) = 0. This results in a singlechannel application up to SIL 1 or up to SIL 2 for proven-in-use devices.
At least two redundant devices are required for SIL 3 with proven-in-use devices.
At least three redundant devices are required for SIL 3 without proven-in-use devices.

9Competence in Functional Safety
Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves

5

Intended use of control valves insafety-instrumented systems

Responsibility

The reliability of mechanical components is significantly affected by the operating conditions and, as a result, by systematic failures. This needs to be taken into account whenselecting and sizing devices.

Safety-instrumented function
During normal operation, the signal pressure is applied to the pneumatic actuator. To
meet the requirements of the safety-instrumented function, the actuator is usually vented
by a solenoid valve. The force of the actuator springs moves the valve to its end position,i.e. the valve is either completely opened or closed.
The end position of the valve must not be impeded by mechanical equipment, such as travel stops or handwheels, under any circumstances.

When the signal pressure is applied to the actuator again, the valve moves to the corresponding position. If the actuator is to be locked after a case of demand, this must be
ensured by the operator using suitable means.

Operator

Features of final elements
Contact with the process media may cause systematic failure and, as a result, affect thesafety-related availability of the safety-instrumented systems. The influence of specificprocess conditions must be analyzed and taken into account during sizing and maintenance.

These conditions arise from process requirements. To rule out systematic failure, we recommend creating a loop data sheet according to the German standard VDI 2180-5,
section 4 (recommendations for final elements).
In case of doubt, consult the manufacturer for valve sizing.

To reduce systematic failure, diverse redundancies may be advantageous (e.g. globe
valve and ball valve).

10

OperatorCompetence in Functional Safety
Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves

Responsibility
The joint use of a control valve within the safety loop by a control loop of a basic

process control system makes it possible to increase the diagnostic coverage of thesafety-instrumented system. This joint use can lead to additional risk. This aspect must
be taken into account in the risk analysis.


Online tests, such as the partial stroke test and other diagnostic processes integrated

into the valve positioner, can be regarded as state-of-the-art test methods. They canbe used to lengthen the proof test interval or to improve the safety margin (discovery
of undetected systematic failures).
VDI 2180-5, section 4 provides special instructions.

Avoiding systematic failure
To avoid systematic failure, the user must take into account the following applicationspecific factors besides the manufacturer specifications:Operator
Corrosion (destruction primarily of metals due to chemical and physical processes)
Material fatigue, e.g. in bellows seals

Wear induced by the process mediumAbrasion (material removed by solids contained in the process medium)Medium deposits
Aging (damage caused to organic materials, e.g. plastics or elastomers, by exposure

to light and heat)Chemical attack (organic materials, e.g. plastics or elastomers, which swell, leach out

or decompose due to exposure to chemicals)

If no experience data exist for the devices used, a visual inspection of the safety equipment must be performed after a short time in operation.

11

Competence in Functional Safety
Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves

5.1

General control valve requirements

Responsibility
Operator

For each application, the user must specify the following conditions:Maximum/minimum transit time OPEN  CLOSED or CLOSED  OPENPermissible leakage rateMaximum/minimum supply pressure of the compressed air networkAir capacity available in relation to pressure Connecting pipe cross-sections must be adhered to.

Nominal size (connection length ≤ 2 m)

Manufacturer

KVS coefficient
0.16 · 0.32

1.4

4.3

–
9

Connection
Pressure (bar)4

1 and 34

≥ 1.4

≥ DN 6≥ DN 8≥ DN 10≥ DN 6≥ DN 8≥ DN 4≥ DN 6≥ 2.5≥6≥ DN 4≥ DN 4

Note: A larger nominal size is needed when the connection length exceeds 2 m.



Example: Connecting pipe cross-sections required for SAMSOMATIC Type 3963 Solenoid ValveSAMSON uses calculation methods to predict the transit time and to size the pneumatic
hook-up. SAMSON can support users in selecting devices on request.
The seat shut-off performance (leakage rate) must be tested at regular intervals by
performing plausibility checks while the process is running ormeasuring it on a leakage test bench.

The type of test depends on the application.
The external leakage (fugitive emissions) must be tested at regular intervals, e.g. by spraying with foaming agent.
The conditions depend on the process requirements.

12

Manufacturer
OperatorCompetence in Functional Safety
Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves

5.2 Globe valve requirements

Responsibility
If there is a risk of solids contained in the process medium causing blockage,a strainer must be fitted.

Operator

Safety equipment with fail-open action must not be operated withstrainers.
To reduce friction, it is preferable to use spring-loaded stem packings. Adjustable stem

packings are to be tightened by qualified staff only to prevent the stem from becoming blocked.

OperatorTo prevent corrosion of the actuator springs, measures must be taken to prevent wateror moisture from entering the actuator. Such measures include fitting a venting pipe or
air purging of the actuator‘s spring chamber.

   
Example:Control and quick-acting shut-off valve with air purging of theactuator‘s spring chamber

Example:On-off valve with air purging of the actuator‘s spring chamber

Suitable measures must be taken to ensure that the venting port of the solenoid valve

is kept open.

Manufacturer/
operator

Example: Venting pipe on the solenoid valve

13Competence in Functional Safety
Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves

Responsibility
It is essential to check the actuator forces to ensure that the valve can overcome

the process pressures to reach its fail-safe position.
This can be checked by the manufacturer if requested.

The actual actuator forces must not close the valve against a pressure which is 1.5

times above the nominal pressure (PN) of the plant or valve.
If this actuator force restriction cannot be implemented, an excess pressure valve isnecessary for valves connected in series to prevent that the permissible operatingpressure is exceeded.

Manufacturer/
operator

Example: Valves connected in series
It is essential to observe the prescribed direction of flow (arrow on the valve body) ofglobe valves.

14

OperatorCompetence in Functional Safety
Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves

5.3 Ball valve requirements

Responsibility

Note for ball valves that higher initial breakaway torques arise as the differential pressureof the process medium rises, requiring higher actuator torques.

Differential pressure ∆p (bar)

0

3

6

10

16

40

8

9

11

14

18

28

20

26

35

52

33

36

42

73

DN

Mdmax
(Nm)

Md (Nm)

15

60

3

5

5

5

25

240

5

10

10

10

40

450

10

20

20

50

450

15

30

30

Manufacturer

Mdl (Nm)

80

750

25

60

60

66

72

86

144

100

750

40

90

90

105

120

140

251

150

3160

60

120

120

160

210

290

450

Max. permissible torque, required torques and initial breakaway torques
Example: Torque specifications for a ball valve

Media, especially degreasing, swelling and fibrous media, may affect the torque.

OperatorThe operating conditions, e.g. switching interval and the medium temperature, havean effect on the torques.

The mounting of the valve and actuator is of vital importance.

ManufacturerThe permissible torques for the ball valve shaft, shaft adapter and bridge have beenverified by the manufacturer. As a result, the max. torque of the actuator (air or spring
torque) must not exceed these torques under any circumstances.
The corresponding specifications in accordance with DIN EN ISO 5211/DIN EN 15081(NAMUR Recommendation NE 14) must be observed

Flange type

F03

F04

F05

F07

F10

F12

F14

F16

F25

F30

F35

F40

F48

F60

Maximum torque of theattachment flanges (Nm)

32

63

125

250

500

1000

2000

4000

8000

16000

32000

63000

125000250000Maximum torque of the attachment flanges according to DIN EN ISO 5211

15

Competence in Functional Safety
Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves

5.4 Butterfly valve requirements

ResponsibilityOn sizing actuators for butterfly valves, note that the actuator must provide suf-

ficient torque to overcome the breakaway torque and closing torque in closed
position as well as the dynamic torque in open position.

On mounting the actuator on the butterfly valve, the breakaway torque of the but-

terfly valve in relation to the differential pressure and the permissible torque of thebutterfly valve shaft must be observed.

Nominal size
DN

NPS

Perm. torqueMdmax (Nm)Manufacturer

Perm. torque Mdl in Nm at a differential pressure∆p (bar)
0 bar

5 bar

10 bar

16 bar

80

3

280

40

43

45

51

100

4

280

48

54

59

67

150

6

505

91

106

114

157

200

8

785

190

219

269

288

250

10

785

320

364

433

480

300

12

1591

370

467

578

654

400

16

3215

690

903

1089

1239

Example: Required manufacturer specifications

Note that high dynamic torques can arise at high differential pressures in the process

medium, pushing open the butterfly disc.

Dynamic torque of butterfly valves in relation to the opening angle

16

OperatorCompetence in Functional Safety
Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves

Responsibility
Media, especially degreasing, swelling and fibrous media, may affect the torque.

OperatorThe operating conditions, e.g. switching interval and the medium temperature, havean effect on the torques.

The mounting of the valve and actuator is of vital importance.
The permissible torques for the butterfly valve shaft, shaft adapter and bridge have

Manufacturer

been verified by the manufacturer. As a result, the max. torque of the actuator (airor spring torque) must not exceed these torques under any circumstances.
The corresponding specifications in accordance with DIN EN ISO 5211/DIN EN 15081(NAMUR Recommendation NE 14) must be observed. See section 5.3 on ball valve
requirements.

17

Competence in Functional Safety
Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves

5.5 Rotary plug valve requirements

ResponsibilityOn sizing actuators, note that the actuator must provide sufficient torque to over-come the closing torque in closed position as well as the dynamic torque in open
position.


Adjustable stem packings are to be tightened by qualified staff only to prevent thestem from becoming blocked.

OperatorTo prevent corrosion of the actuator springs, measures must be taken to prevent wateror moisture from entering the actuator. Such measures include fitting a venting pipeor air purging of the actuator‘s spring chamber.

The proper mounting of the valve onto the actuator is of vital importance.

ManufacturerThe permissible torques for the valve shaft, shaft adapter and bridge have beenverified by the manufacturer. As a result, the max. torque of the actuator (air or
spring torque) must not exceed these torques under any circumstances.
The corresponding specifications in accordance with DIN EN ISO 5211/DIN EN 15081(NAMUR Recommendation NE 14) must be observed. See section 5.3 on ball valve
requirements.

5.6 Proof tests and service lifeThe proof test interval and the extent of the test lie within the operator‘s responsibility.

This must be documented correspondingly.

During the proof test, suitable means must be used to test the control valve to ensure

its proper functioning. Worn components must be replaced by original spareparts from the manufacturer.


The maximum service life must be specified.

It is recommended to summarize the requirements of the proof test in a checklist.

Refer to Appendix 2 for an example.

18

OperatorCompetence in Functional Safety
Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves

6

Installation, piping and wiring

Responsibility

6.1 Mechanical and pneumatic installation

During mechanical and pneumatic installation, the mounting and operating instructionsof the corresponding device must be observed.
The pneumatic connection must only be connected to instrument air networks that meetthe quality requirements in accordance with ISO 8573-1:2001, Class 3 or 4.

Operator

Compressed air quality according to ISO 8573-1
Particle size and quantity

Oil content

Pressure dew point

Class 4

Class 3

Class 3≤ 5 μm and 1000/m³≤ 1 mg/m³–20 °C or at least 10 K below the lowest ambient temperature to be expected
The required minimum cross-sections of the supply air lines must be observed. Refer tosection 5.1 (General control valve requirements).
After mounting, the position of the filters or filter check valves on the valve accessories,
e.g. pilot valves, must be checked and, if necessary, corrected.

Operator

Example: Pilot-controlled Ex i solenoid valve (SAMSOMATIC)The prescribed mounting position of the devices must be observed.

Booster valve ports not connected by pipe or hose must be protected properly against

dirt, water etc. from entering the device by using appropriate filters.

19Competence in Functional Safety
Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves

6.2 Electrical installation
Only cables with the prescribed outer diameter of the cable glands may be used.

Responsibility
Operator
For EExi circuits the electrical cable data must comply with the data taken as

the basis during planning.

Cable glands and cover screws must be fastened tightly to ensure that the degree ofprotection is met.


Only devices with suitable equipotential bonding may be connected.

The installation regulations for the respective explosion protection measures must be

observed.


Prior to start-up, the voltage must be checked to ensure that it meets the permissible

range.


Prior to start-up, the necessary verifications (verification of intrinsic safety) must be

available.

The effect of disturbances to lines must be checked, especially– disturbance caused by EMC influences and– disturbance caused by capacitance influences when long lines are used (risk thata solenoid valve remains energized).

The special conditions specified in the explosion protection certificates must be

adhered to.

6.3 Installation of control valves
Control valves must be installed free of stress and with low degrees of vibration.

After installation, the flange joints must be checked for leaks.
The pipeline must be rinsed prior to installing the control valve.

20

OperatorCompetence in Functional Safety
Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves

ResponsibilityTo ensure the control valve functions properly, the pipeline must be designed to bestraight and without any manifolds or disturbances for a distance of at least six times
the pipe size (DN) upstream and downstream of the valve.

It must be checked whether the mounting position of the control valve complies withthe manufacturer‘s specifications (operating instructions).


The devices used must be checked to ensure they are suitable for use under theprevailing ambient conditions (temperature, humidity etc.).

While installing the control valves, sufficient space must be left to remove the valve

for maintenance.


The wiring and function of devices must be documented in a wiring plan.

A3

+81

-82

+11

-12

+83

-84

A2

+51

-52

+41

A1

G

-42

+31

-32

Main cable route
Instrument air manifold

Example: Wiring plan for a control valve with positioner, solenoid valve and limit signals

21

Competence in Functional Safety
Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves

7

Applicable device documentation

Each control valve has a data sheet, mounting and operating instructions as well as a certificate of conformity inaccordance with the European Pressure Equipment Directive (PED) 2014/68/EU and, if applicable, an explosion
protection certificate. These documents are available in various languages on the Internet at www.samson.de,www.vetec.de, www.pfeiffer-armaturen.com and www.leusch.de.

8

Appendix 1 – Manufacturer‘s declarations


Series 240 und 250 Globe Valves with Type 3271 and 3277 Pneumatic Actuators(valve manufacturer: SAMSON AG)

Type LTR43 Butterfly Valve with actuator(valve manufacturer: LEUSCH GmbH Industriearmaturen)Series 1a and 1b Globe Valves with Type 3271 and 3277 Pneumatic Actuators(valve manufacturer: PFEIFFER Chemie-Armaturen GmbH)
Series 20a and 20b Ball Valves with Series 31a Actuator(valve manufacturer: PFEIFFER Chemie-Armaturen GmbH
Series BR 26d Ball Valve with Series 31a Actuator(valve manufacturer: PFEIFFER Chemie-Armaturen GmbH)
Series 14b and 14c Butterfly Valves with Series 31a or 30 Actuators(valve manufacturer: PFEIFFER Chemie-Armaturen GmbH)
Series 72 and 73 Rotary Plug Valves with Type AT, R and M Pneumatic Actuators(valve manufacturer: VETEC Ventiltechnik GmbH)

22

Competence in Functional Safety
Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves23Competence in Functional Safety
Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves24Competence in Functional Safety
Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves

025

Competence in Functional Safety
Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves

026Competence in Functional Safety
Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves

027

Competence in Functional Safety
Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves

028Competence in Functional Safety
Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves29Competence in Functional Safety
Functional safety of globe valves, rotary plug valves, ball valves and butterfly valvesCompetence in Functional Safety
Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves

2 −2Example
of a checklist
for a finalfor
element
99 Appendix
Appendix− Exampleof a checklist
a final element

Checklist for testing safety equipment
Final element test

Yes

No

Is the tag documentation complete and up-to-date?
Are the connecting cables in good order?
Are the screw fittings in good order?
Is the labeling complete and in a readable state? Control room, on site, process control system and safety PLC
Are all connecting housings free of moisture, water, oil and dust? (solenoid valve, feedback etc.)
Are the actuator or solenoid valve free of corrosion? Paint finish in good order?
Visual inspection of the pneumatic system: Are all pneumatic connections in good order and leak-tight?
Are the bridges, yokes, stem connectors, fastening nuts free of corrosion and fastened properly?
Is the valve packing leak-tight? Are there any visible signs of the process medium?
Is the bellows seal/bellows monitoring still in good order?
Check of the exhaust ports of the solenoid valve
Fail-safe position check
Open final element inprocess control system
P&ID

Fail Close

Loop

Set to Manual and move
DCS

* Valve: Remove air hose at the air manifold
while the valve is being moved!

Valve

Do the valve position and output signal match? Move valve to OPEN and CLOSED positions!
Does the actuator move smoothly to its operating position when the signal pressure is applied?
Is there any leakage at the actuator?
Does the actuator move smoothly to its fail-safe position when moved by the springs?
Valve transit time
Closing time
Fail-close position
Permissible leakage rate

N/A

Time to open the valve

N/A

Time allowed for the valve
to move to its fail-safe position

sec.

Time to close the valve

sec.

sec.

Valve closing time to fail-safe
position

N/A

Leakage rate allowed in
fail-safe position
1/min, m³/minsec.

Leakage rate measured
in fail-safe position
1/min, m³/min

To measure the leakage rate, the valve must be removed from the pipeline and tested in the workshop.
Refer to DIN EN 12266-1 (A.4 Seat tightness) for the test procedures.
The following table contains the permissible leakage rates.
For control valves functioning as safety equipment, leakage can also be measured according to DIN EN 1349.
Test medium
LiquidGas

Leakage rate A

Leakage rate B

Leakage rate C

Leakage rate D

Leakage rate E

Leakage rate F

Leakage rate G

Liquid
No visible
leaks foundduring test

0.01 *DN

0.03 *DN

0.1 *DN

0.3 *DN

1.0 *DN

2.0 *DN

0.3 *DN

3.0 *DN

30.0 *DN

300 *DN

3000 *DN

6000 *DN

The leakage rates only apply when room temperature prevails at the outlet side. “No visible leaks found during test“ meansno visible moisture or formation of drops or bubbles. This corresponds to a lower leakage rate than leakage rate B.
Attach green label after the test has been completed.
Does repair work need to be performed on the system? If this is the case, write out a separate order.
Tester 1:

30

30

Tester 2:

Test date:

Signature:

Competence in Functional Safety
Functional safety of globe valves, rotary plug valves, ball valves and butterfly valvesCompetence in Functional Safety
Functional safety of globe valves, rotary plug valves, ball valves and butterfly valves

Checklist for testing safety equipment
Owner

Created/Revised by:Operation:

Plant:

Subplant:

Tag no.:Operating state during test:
Prüfung:
Shutdown

PLC/DCS:

Tester:Test date:
Measuring principle:

Fail-safe position:

SIL level:

Architecture:

Manufacturer:

Manufacturer model:

Body number/serial number/stamp number/ID:

Site of installation:

Barrier medium:+H551-14E2

Final element exists in the following SIL loops
SIF no.:Commissioning test:

Proof test:

Revision test:

Final element test

Lockout test……. years……. years- An assessment of the process and safety hazards in the plant and installation is necessary.
- Obtain a permit to work!
- Wear suitable protection for the work! Observe explosion protection regulations!
- The person performing the work is responsible for using the appropriate maintenance methods according to the recognized codesof practice as well as for using suitable and tested tools!
- The person performing the work bears the compulsory insurance during the work!
This includes, for example, the safeguarding of the workplace against unauthorized access or against accidental contact with
unprotected electrical installations while temporarily leaving the workplace.
- Take precautionary measures to protect the plant against external influences, such as weather or other damaging environmental
influences.
Measuring equipment list:
Type/Manufacturer/model:

Serial number:

Type/Manufacturer/model:

Serial number:

Type/Manufacturer/model:

Serial number:

Type/Manufacturer/model:

Serial number:

Type/Manufacturer/model:

Serial number:

Type/Manufacturer/model:

Tester 1:

Serial number:

Tester 2:

Test date:

Signature:

31

31

MANUAL

Competence in Functional Safety

SAMSON AKTIENGESELLSCHAFT
Weismuellerstrasse 3 · 60314 Frankfurt am Main; Germany
Phone: +49 69 4009-0 · Fax: +49 69 4009-1507
E-mail: samson@samson.de · Internet: www.samson.de

SMART IN FLOW CONTROL.

Subsidiaries

2017-01 · WA 236 EN

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