SIL Safety Manual

DOC.SILM.EF.EN Rev. 0
March 2015

EL-O-Matic F-Series Pneumatic Actuator

SIL Safety Manual

EL Matic TM
EL-O-Matic F Contents
DOC.SILM.EF.EN, Rev. 0 March 2015

Table of Contents
Section 1: Functional Specification .......................................1

Section 2: Configuration of the Product ...............................2

Section 3: Service Condition Limitations

(Limitation of Use) ...............................................3

Section 4: Expected Lifetime ................................................4

Section 5: Failure Modes and Estimated Failure Rates ..........5

Section 6: Installation and Site Acceptance Procedure .........6

Section 7: Periodic Test and Maintenance Requirements .....7

7.1 General....................................................................................................... 7

7.2 Full-Stroke Test........................................................................................... 7

7.3 Partial-Stroke Test....................................................................................... 8

7.4 Proof Test and Periodic Maintenance........................................................... 8

Section 8: Hardware Fault Tolerance ...................................9

Section 9: Classification ......................................................10

Section 10: Safe Failure Fraction ...........................................11

Section 11: Mean Repair Time ..............................................12

Section 12: Systematic Capability .........................................13

Section 13: Document Revision ............................................14

Table of Contents I
SIL Safety Manual Section 1: Functional Specification
DOC.SILM.EF.EN, Rev. 0 March 2015

Section 1: Functional Specification

The safety function for El-O-Matic F-Series pneumatic actuator is defined as follows:

Double-Acting Scenario:
a. When an unsafe condition is detected in a plant by a process sensor, the
controller, via actuator control system, drives the Actuator to close the
shut-down valve, depressurizing (if under pressure) the Opening side of
the actuator and pressurizing the Closing side of the actuator.
b. When an unsafe condition is detected in a plant by a process sensor, the
controller, via actuator control system drives the Actuator to open the
blow-down valve, depressurizing (if under pressure ) the Closing side
of the pneumatic actuator and pressurizing the Opening side of the
pneumatic actuator.

Single-Acting Scenario:
a. When an unsafe condition is detected in a plant by a process sensor, the
controller, via actuator control system drives the Actuator to rotate with
sufficient torque to move a valve to its fail-safe state when hold-position
air pressure is released.

The El-O-Matic brand Actuator Selection Procedure provides functional definition with
specifics on input variables and performance.

In any case, the choice of the safety function to be implemented is responsibility of the
system integrator.

Functional Specification 1
Section 2: Configuration of the Product SIL Safety Manual
March 2015 DOC.SILM.EF.EN, Rev. 0

Section 2: Configuration of the Product

The El-O-Matic F-Series are pneumatically operated actuators designed to operate Ball /
Plug / Butterfly valves, automation of louvers and dampers & automation of any quarter-
turn mechanism. Both the double-acting and single-acting (spring-return) versions of
the El-O-Matic F-Series pneumatic actuators are designed in such a way that there are no
moving parts on the outside (with the exception of the position indicator). This makes
them safe, easy to install and virtually maintenance free.
For further details about actuator configurations, please refer to the El-O-Matic F-Series
product data sheets, Safety guide and Installation, Operation and Maintenance manual.

2 Configuration of the Product

SIL Safety Manual Section 3: Service Condition Limitations (Limitation of Use)
DOC.SILM.EF.EN, Rev. 0 March 2015

Section 3: Service Condition Limitations

(Limitation of Use)
The operating capabilities are listed below:

• Maximum Operating Pressure:

—— Pneumatic Service
—— Up to 120 psig (8.3 barg)

• Ambient Temperature:
Temperature extremes require different solutions to maintain actuator operational
integrity and reliability. For each El-O-Matic F-Series actuator is available in three
different temperature executions.
—— -20°C to +80°C (-4°F to +176°F) Standard temperature
—— -20°C to +120°C (-4°F to +250°F) High Temperature
—— -40°C to +80°C (-40°F to +176°F) Low Temperature

• Torque Output Range:

—— Double-Acting El-O-Matic F-Series actuators, requiring pressure to rotate
in either direction, are available with a torque range between 4.8 Nm
(44 lbf.in) and 6,490 Nm (59000 lbf.in)
—— The El-O-Matic F-Series spring-return models require pressure in only one
direction of travel and are suitable for air-fail close and air-fail to open
applications without modification. These models are available with a
spring end torque between 2 Nm (20 lbf.in) and 2394 Nm (21000 lbf.in)

• Safety Function:
For spring-return models, the safety function is self-evident performed by the
springs. The safety function of double-acting models should be performed by the
A-chamber for safety related systems.

Figure 1 Use the A-Chamber for Safety Related Systems on Double-Acting Actuators

Assembly Code: CW Assembly Code: CC

= Safety Function is = Safety Function is
Counterclockwise Rotation Clockwise Rotation

B A
A B
Pinion

Pistons A B A B Pistons

Service Condition Limitations (Limitation of Use) 3

Section 4: Expected Lifetime SIL Safety Manual
March 2015 DOC.SILM.EF.EN, Rev. 0

Section 4: Expected Lifetime

Actuator lifetime (for which failure rates indicated in Par. 5 are ensured) strongly depends
on operating conditions.

For normal service conditions, EL-O-Matic F-Series actuators can be in good conditions
also after more than 10 years with planned minimum maintenance. Normal working life is
500.000 cycles. El-O-Matic F-Series carry a warranty period of:

• 18 months after delivery if properly stored in conditions that we declare or

• 12 months after installation on site.

4 Expected Lifetime
SIL Safety Manual Section 5: Failure Modes and Estimated Failure Rates
DOC.SILM.EF.EN, Rev. 0 March 2015

Section 5: Failure Modes and Estimated

Failure Rates
Table 1. Failure Modes and Estimated Failure Rates – El-O-Matic F-Series Actuator
Failure Mode Estimated Failure Rate [1/h]
Failure on demand to Close/Open (FTC/FTO) -
5.24E-08
El-O-Matic F-Series Double-Acting
Failure on demand to Close/Open (FTC/FTO) -
4.63E-08
El-O-Matic F-Series Single-Acting

NOTICE
No internal diagnostics is included in the device. These numbers are valid when taken in
account the maintenance interval and procedure described in Section 7.

Failure Modes and Estimated Failure Rates 5

Section 6: Installation and Site Acceptance Procedure SIL Safety Manual
March 2015 DOC.SILM.EF.EN, Rev. 0

Section 6: Installation and Site

Acceptance Procedure
Any necessary installation and site acceptance procedures are discussed in the EL-O-Matic
F-Series actuators Installation, Operation and Maintenance manual. The Installation,
Operation and Maintenance manual defines exercising of the actuator after installation and
defines testing after maintenance.

6 Installation and Site Acceptance Procedure

SIL Safety Manual Section 7: Periodic Test and Maintenance Requirements
DOC.SILM.EF.EN, Rev. 0 March 2015

Section 7: Periodic Test and

Maintenance Requirements
7.1 General
Please consider that the information in this paragraph are relevant only in regards of
Reliability Tests; please refer to Doc. Installation, Operation and Maintenance manual for
detailed information about product maintenance, handling and storage.

Diagnostic tests may be made to increase the system reliability (Full-Stroke or Partial-
Stroke Test).

“On site” tests depend on Project/Plant facilities/requirements; however, a functional test

must be executed on site, prior actuator operation.

7.2 Full-Stroke Test

The “Full-Stroke Test” (“On-line”) must be performed to satisfy the PFDAVG (average
probability of failure on demand) value.

The full-test frequencies will be defined by the final integrator in relation to the defined SIL
level to achieve.

• Procedure:

—— Operate the Actuator/Valve assembly for No. 2 open/close complete

cycles with complete closing of the valve.

—— Verify the Correct performing of open – close manoeuvre (for example,

check locally, or automatically via Logic solver, the correct movement of
the actuator/valve).

Considering the application of the above described Full-Stroke Test procedure, the “Test
Coverage” can be considered 99%.

Periodic Test and Maintenance Requirements 7

Section 7: Periodic Test and Maintenance Requirements SIL Safety Manual
March 2015 DOC.SILM.EF.EN, Rev. 0

7.3 Partial-Stroke Test

The “Partial-Stroke Test” (“On-line”) can be performed to improve the PFDAVG value.

A typical partial-stroke value is 15% of the stroke.

The “Partial-Stroke Test” (“On line”) can be performed to satisfy PFDAVG (average
probability of failure on demand) value.

• Recommended Test Interval = 1 to 3 months.

• Procedure:

—— Operate the Actuator/Valve assembly for No 1 open/close cycles 15/20%

of the stroke.

—— Verify the Correct performing of partial-stroke operation (for example,

check locally, or automatically via Logic solver, or via the PST system the
correct movement of the actuator/valve till 15/20% of the stroke).

The above parameters to check will depend from the partial-stroke test system available.
Considering the application of the above described Partial-Stroke Test procedure, the
“Diagnostic Coverage” is >90 %.

7.4 Proof Test and Periodic Maintenance

We advise to perform the following checks upon each proof test interval complying with
the rules and regulations of the country of final installation:

• Visually check the entire actuator as well as the control system (where foreseen).
• Ensure there are no leaks on the actuator parts under pressure.
• Check pneumatic connections for leaks. Tighten tube fittings as required.
• Check if manual override (where foreseen) is regular.
• Check if pneumatic filter cartridge (where foreseen) is sound and filter bowl
(where foreseen) has been cleaned properly.
• Check the setting of the relief valves (where foreseen).
• Verify that the power fluid supply pressure value is within the required range.
• Remove built-up dust and dirt from all actuator surfaces.
• Inspect actuator paint work for damages to ensure continued corrosion protection.
Touch-up as required in accordance with the applicable paint specification.
• Operate the Actuator/Valve assembly for No 2 open/close complete cycles with
complete closing of the valve.
• Verify the correct performing of open – close operations (for example, check
locally, or automatically via Logic solver, the correct movement of the actuator).

The Installation, Operation and Maintenance manual defines a minimum maintenance

interval after 500.000 cycles for the EL-O-Matic F-Series actuators. This addresses
components that may have age related degradation. When the maintenance interval has
elapsed a complete overhaul of the actuator is required.

8 Periodic Test and Maintenance Requirements

SIL Safety Manual Section 8: Hardware Fault Tolerance
DOC.SILM.EF.EN, Rev. 0 March 2015

Section 8: Hardware Fault Tolerance

The HFT of the device is 0.

The requirements of minimum hardware fault tolerance (HFT) according to Tab.6 of IEC
61511-1 have to be observed but, as long as has been performed an assessment report
fully in compliance with IEC 61508 part 1 to7, alternative fault tolerance requirements
have to be considered applicable according to Table 2 of IEC 61508-2 as per par. 11.4.5
of IEC 61511-1.

Hardware Fault Tolerance 9

Section 9: Classification SIL Safety Manual
March 2015 DOC.SILM.EF.EN, Rev. 0

Section 9: Classification
The equipment is classified Type A according to IEC 61508-2.

10 Classification
SIL Safety Manual Section 10: Safe Failure Fraction
DOC.SILM.EF.EN, Rev. 0 March 2015

Section 10: Safe Failure Fraction

SFF=0 without external diagnostic tests.

SFF>0 with external diagnostic tests, carried out according to definition 3.8.7 of IEC 61508-4.

• SFF = 91% with Partial-Stroke Test.

• SFF = 99% with Full-Stroke Test.

The SFF shall be evaluated for the entire final element sub-system.

The diagnostic test shall be performed considerably more often than the demand of the
safety function.

Safe Failure Fraction 11

Section 11: Mean Repair Time SIL Safety Manual
March 2015 DOC.SILM.EF.EN, Rev. 0

Section 11: Mean Repair Time

The MRT of the device is 1 hour.

NOTICE
The MRT is estimated considering availability of skilled personnel for maintenance, spare
parts and adequate tools and materials on site (that is, it encompasses the effective time to
repair and the time before the component is put back into operation).

Procedures to repair or replace the EL-O-Matic F-Series actuators are provided in the
respective Installation, Operation and Maintenance manual. Please refer to the Installation,
Operation and Maintenance manual for any tools required for repair and replacement and
required competency of technicians. Maintenance and subsequent test procedures are
also covered in the Installation, Operation and Maintenance manual. Any failures, identified
by the end-user during maintenance, repair or proof testing, that potentially impact the
functional safety of the EL-O-Matic F-Series actuators should be reported back to Actuation
Technologies Customer Service Coordinator.

12 Mean Repair Time

SIL Safety Manual Section 12: Systematic Capability
DOC.SILM.EF.EN, Rev. 0 March 2015

Section 12: Systematic Capability

The systematic capability of the device is 3.

This systematic capability is guaranteed only if the user:

1. Use the device according to the instructions for use and to the present Manual.

2. Use the device in the appropriate environment (limitation of use).

Systematic Capability 13
Section 13: Document Revision SIL Safety Manual
March 2015 DOC.SILM.EF.EN, Rev. 0

Section 13: Document Revision

Table 2. Revision Overview
ECN DATE REV BY * DATE
PRE RELEASE 00A ORIGINATOR J. Zorgdrager 27 January 2015
CHECKED R. Ouwendijk 27 January 2015
APPROVED

14 Document Revision
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