Dräger Polytron 8000/8200/8700/8720

Transcription

1 Dräger Polytron 8000/8200/8700/8720 Safety Manual Vers. 2.0 Rev. R1, Feb. 2012

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3 Content Content 1 Scope and purpose of safety manual Relevant standards For your safety General safety statements Defnton of alert cons Feld of applcaton Assumptons and restrctons for usage of the gas transmtter General Tranngs Installaton Mantenance Calbraton Replacement Hardware and/or SW Confguraton Use of Accessores Access Rghts opton Proof test Proof Test Frequences Vsual Inspecton Proof Test Gas Response Proof Test Test of the 4 to 20 ma output Test of the relay outputs Safety relevant parameters Condtons of use General Access restrctons SIL actvaton Proof tests Flters Relays to 20 ma output Polytron / Polytron Polytron 8200 DD Polytron Safety functons General Safety ntegrty level Safety accuracy Falure rates Polytron / Polytron Polytron 8200 DD Polytron Reference documents Lst of Abbrevatons Safety Manual 3

4 Scope and purpose of safety manual 1 Scope and purpose of safety manual The purpose of ths safety manual s to document the necessary nformaton and assumptons that are requred for the ntegraton of the assessed gas transmtters Dräger Polytron 8000 Dräger Polytron 8200 DD Dräger Polytron /340 Dräger Polytron 8720 nto a safety nstrumented system (SIS) - n complance wth the requrements of IEC standard. The safety manual specfes the safety functons. Ths may be used to support the safety functon of a safety nstrumented system (SIS). The safety manual provdes the assumptons that have been made on the usage of the gas transmtter. If those assumptons cannot be met by the applcaton, the SIL (Safety Integrty Level) capablty has to be evaluated consderng the applcaton-specfc crcumstances. 2 Relevant standards EN 50402:2005 IEC 61508:2010 Electrcal apparatus for the detecton and measurement of combustble or toxc gases or vapours or of oxygen requrements on the functonal safety of fxed gas detecton systems Functonal safety of electrcal / electronc / programmable electronc safety-related systems 3 For your safety 3.1 General safety statements Safe connecton of electrcal devces Never connect ths nstrument to other electrcal devces as mentoned n the IFU before consultng the manufacturer or an expert. Use n areas subject to exploson hazards Instruments or components for use n exploson-hazard areas whch have been tested and approved accordng to natonal, European or nternatonal Exploson Protecton Regulatons may only be used under the condtons specfed n the approval and wth consderaton of the relevant legal regulatons. The nstruments or components may not be modfed n any manner. The use of faulty or ncomplete parts s forbdden. The approprate regulatons must be observed at all tmes when carryng out repars on these nstruments or components. Before usng ths equpment, carefully read the Instructons for Use (IFU). Strctly follow the Instructons for Use. The user must fully understand and strctly observe the nstructons. Use the equpment only for the purposes and under the condtons specfed n the Instructons for Use. Comply wth all local and natonal laws, rules and regulatons assocated wth ths equpment. Only traned and competent personnel are permtted to nspect, repar and servce the product as detaled n the Instructons for Use. Further mantenance work that s not detaled n these Instructons for Use must only be carred out by Dräger or personnel qualfed by Dräger. Dräger recommends a Dräger servce contract for all mantenance actvtes. Use only genune Dräger spare parts and accessores, otherwse the proper functonng of the equpment may be mpared. The threads for the exploson proof enclosure do not conform to the mnmum/maxmum values n EN/IEC The threads must not be reworked by the user. Do not dspose of the Safety Manual. Ensure that they are retaned and approprately used by the equpment user. The measurng functon of the gas detecton transmtter for exploson protecton, accordng to Annex II, clauses 1.5.5, and of Drectve 94/9/EC s currently not covered. Substtuton of components may mpar ntrnsc safety. Only f ntrnsc safety s nvolved. Safe connecton of electrcal devces Never connect ths nstrument to other electrcal devces as mentoned n the Instructons for Use before consultng the manufacturer or an expert. 4 Safety Manual

5 Feld of applcaton Usng the product n areas subject to exploson hazards: Instruments or components for use n exploson-hazard areas whch have been tested and approved accordng to natonal, European or nternatonal Exploson Protecton Regulatons may only be used under the condtons specfed n the approval and wth consderaton of the relevant legal regulatons. The nstruments or components may not be modfed n any manner. The use of faulty or ncomplete parts s forbdden. The approprate regulatons must be observed at all tmes when carryng out repars on these nstruments or components. 3.2 Defnton of alert cons The followng alert cons are used n ths document to provde and hghlght areas of the assocated text that requre a greater awareness by the user. A defnton of the meanng of each con s as follows: 4 Feld of applcaton Ths Safety Manual refers to the heren consdered models of the product famly Polytron 8XX0 gas transmtters for statonary, contnuous montorng of gases and vapours n a sutable atmosphere. The Polytron /340 gas transmtter montors the concentraton of combustble gases and vapours contanng hydrocarbons. The Polytron 8720 gas transmtter montors the concentraton of carbon doxde. The Polytron 8200 DD gas transmtter montors the concentraton of combustble gases and vapours contanng hydrocarbons and /or H 2. The Polytron 8000 gas transmtter montors the concentraton of toxc gases and vapours or oxygen. The gas transmtter uses mcroprocessor technology to montor the gas concentraton and update the outputs accordngly. Dependng on the model, the outputs are WARNING Indcates a potentally hazardous stuaton whch, f not avoded, could result n death or serous njury. CAUTION Indcates a potentally hazardous stuaton whch, f not avoded, could result n physcal njury, or damage to the product or envronment. It may also be used to alert aganst unsafe practces. Indcates addtonal nformaton on how to use the devce. 1. one 4 to 20 ma analogue sgnal output, where 4 ma represents 0 % of confgured range and 20 ma represents 100 % of confgured range. 2. two alarm relays and a fault relay output, addtonally to the above mentoned 4 to 20 ma output. The gas transmtter s desgned for one-man calbraton and offers a varety of dagnostcs and self test features. Dfferent measured gases are lsted n an nternal gases lbrary (only Polytron 87X0). For all these gases, an ndvdual lnearzaton of the output sgnal correspondng to the measured gas concentraton s provded. Confguraton and calbraton are menu guded and easy to perform, usng a HART 1 handheld termnal or HMI of the Polytron 8XX0 product famly. The safety manual s referrng to the followng models of Polytron 8XX0 product famly: Model Software release Dräger Polytron Dräger Polytron 8700 Type Dräger Polytron 8700 Type Dräger Polytron Dräger Polytron 8200 DD HART s a regstered trademark of HCF, Austn, Texas, USA. Safety Manual 5

6 Feld of applcaton Model Part No. Dräger Polytron 8000 Dräger Polytron 8000 d A 4-20/HART Dräger Polytron 8000 d A 4-20/HART relay Dräger Polytron 8000 d S 4-20/HART Dräger Polytron 8000 d S 4-20/HART relay Dräger Polytron 8000 de A 4-20/HART Dräger Polytron 8000 de A 4-20/HART relay Dräger Polytron 8000 de S 4-20/HART Dräger Polytron 8000 de S 4-20/HART relay Dräger Polytron Dräger Polytron d A 4-20/HART Dräger Polytron d A 4-20/HART relay Dräger Polytron d S 4-20/HART Dräger Polytron d S 4-20/HART relay Dräger Polytron e A 4-20/HART Dräger Polytron e A 4-20/HART relay Dräger Polytron e S 4-20/HART Dräger Polytron e S 4-20/HART relay Dräger Polytron 8700 Re 334 e A 4-20/HART Dräger Polytron 8700 Re 334 e A 4-20/HART relay Dräger Polytron 8700 Re 334 e S 4-20/HART Dräger Polytron 8700 Re 334 e S 4-20/HART relay Dräger Polytron Dräger Polytron d A 4-20/HART Dräger Polytron d A 4-20/HART relay Dräger Polytron d S 4-20/HART Dräger Polytron d S 4-20/HART relay Model Part No. Dräger Polytron 8720 Dräger Polytron 8720 d A 4-20/HART Dräger Polytron 8720 d A 4-20/HART relay Dräger Polytron 8720 d S 4-20/HART Dräger Polytron 8720 d S 4-20/HART relay Dräger Polytron 8720 e A 4-20/HART Dräger Polytron 8720 e A 4-20/HART relay Dräger Polytron 8720 e S 4-20/HART Dräger Polytron 8720 e S 4-20/HART relay Dräger Polytron 8720 Re e A 4-20/HART Dräger Polytron 8720 Re e A 4-20/HART relay Dräger Polytron 8720 Re e S 4-20/HART Dräger Polytron 8720 Re e S 4-20/HART relay Dräger Polytron 8200 DD Dräger Polytron 8200 DD d A 4-20/HART Dräger Polytron 8200 DD d A 4-20/HART relay Dräger Polytron 8200 DD d S 4-20/HART Dräger Polytron 8200 DD d S 4-20/HART relay Dräger Polytron 8200 DD e A 4-20/HART Dräger Polytron 8200 DD e A 4-20/HART relay Dräger Polytron 8200 DD e S 4-20/HART Dräger Polytron 8200 DD e S 4-20/HART relay Dräger Polytron 8200 Re DD e A 4-20/HART Dräger Polytron 8200 Re DD e A 4-20/HART relay Dräger Polytron 8200 Re DD e S 4-20/HART Dräger Polytron 8200 Re DD e S 4-20/HART relay Dräger Polytron e A 4-20/HART Dräger Polytron e A 4-20/HART relay Dräger Polytron e S 4-20/HART Dräger Polytron e S 4-20/HART relay Dräger Polytron 8700 Re 340 e A 4-20/HART Dräger Polytron 8700 Re 340 e A 4-20/HART relay Dräger Polytron 8700 Re 340 e S 4-20/HART Dräger Polytron 8700 Re 340 e S 4-20/HART relay 6 Safety Manual

7 Assumptons and restrctons for usage of the gas transmtter 5 Assumptons and restrctons for usage of the gas transmtter 5.1 General For proper nstallaton, operaton, mantenance and calbraton of the gas transmtter and ts accessores strctly follow the Instructons for Use as well as the Assembly Instructons for Accessores. See Instructons for Use for nformaton about assembly and functonal descrpton, operatng condtons and nterface specfcaton. 5.2 Tranngs For avalable tranngs contact DrägerServce Installaton The parametersaton of the gas transmtter must be checked after nstallaton. Also a calbraton and a proof test (see Secton 6 on Page 8) have to be executed. The user has to ensure that the requrements regardng supply voltage and power consumpton, as well as the 4 to 20 ma loop requrements are wthn the specfed range. The accuracy of gas measurement s dependent upon ambent parameters. See Instructons for Use for detals and measurng performance. 5.4 Mantenance The reason for repeated mantenance of the gas transmtter s to ensure the safety functon of the nstrument. Therefore the functonalty, the calbraton and the parametersaton of the gas transmtter has to be checked at regular ntervals takng nto account the applcaton requrements. 5.5 Calbraton For calbraton ensure that only approved and certfed calbraton gas s used n accordance wth the nternal parametersaton of the gas transmtter. If the devaton of the calbraton result s outsde the correspondng lmts lsted n the Instructons for Use, the followng actons are recommended to be performed: Check f the optcal surface areas have not been contamnated (only Polytron 87X0). Check the leak tghtness of the calbraton equpment. Check flters and/or chemcal converters Ensure proper calbraton gas flow. Rerun the calbraton. 5.7 Hardware and/or SW Confguraton The gas transmtter s confgurable over a wde range of settngs. If any settng s changed the parameters must be confrmed by the authorzed personal. Check all parameters lsted on the confrmaton screen. CAUTION Check f the replacng gas transmtter SIL opton has been actvated, f not actvate t. CAUTION The usage of HART sgnal and the usage of the seral output sgnal s not allowed n safety-related applcatons, only the followng outputs may be used n SIL 2 applcatons: a. 4 to 20 ma b. Relays 5.8 Use of Accessores Use only orgnal Polytron /340, Polytron 8720, and Polytron 8200 DD and Polytron 8000 accessores. For nstallaton nformaton, Part No. and descrpton, see Instructons for Use. 5.9 Access Rghts opton Three levels of access rghts and related user groups of dfferent qualfcaton are dstngushed. Operator Shall not know any password to unlock the Polytron 8XX0 for calbraton or modfcaton of parameters. Calbraton personnel Knows the password for calbraton to unlock the Polytron 8XX0 for calbraton purposes and to lock t agan after successful calbraton. Addtonally he can see some parameters but he cannot change any safety-related parameters. Parameterzaton personnel Knows the password to unlock the Polytron 8XX0 for modfcaton and parameterzaton of safety-related parameters. Addtonally he/she can see and modfy all the other parameters too and can make a calbraton. See Instructon for Use for calbraton procedure. 5.6 Replacement If a gas transmtter needs to be replaced (for repar or exchange), the parametersaton of the replacng gas transmtter must be checked. A calbraton and a proof test have to be executed. The tme assumed for replacement s eght hours. 1 DrägerServce s a regstered trademark from Dräger. Safety Manual 7

8 Proof test 6 Proof test All safety-related data are based on repeated proof tests performed at regular ntervals, provded that the proof tests have been successful. Proof testng s an essental part of functonal safety because ths s the only way to reveal dangerous undetected falures. The complance wth these proof test ntervals s under the responsblty of the user of the safety equpment. Durng the proof test the functonal safety s affected and must be ensured by other measures, also organsatonal measures, or the safety nstrumented system needs to be forced and mantaned n a safe state. Not only the gas transmtter needs to be tested, but the safety functon of the whole safety nstrumented system The proof test conssts of the followng steps, as descrbed n the followng chapters. 6.1 Proof Test Frequences Sutable ntervals for nspecton and mantenance have to be defned accordng to the desred applcaton and the SIL capablty. It has to be taken nto account that the calbraton ntervals may be part of the characterzaton of the SIL capablty. Test Frequency per week Frequency per year Vsual Inspecton Proof Test Gas Response Proof Test Test of the 4 to 20 ma output Test of the relay outputs Shall be determned applcaton dependent. 1 EN 50402, 5.2.4, SIL2 applcaton: Must not be exceeded f the transmtter contans flter or chemcal converters. 6.2 Vsual Inspecton Proof Test Vsual nspecton of the Polytron 8XX0 gas detector shall be conducted weekly to confrm that no external blockage of gas/ vapor path nto the sensng chamber exsts, eg. debrs, trash, snow, mud, external equpment, etc. Correctve acton shall nclude removal of such mpedments should they exst. All gas detectors must be nspected to ensure that they are capable of provdng expected performance and protecton. Applcaton dependent, shorter proof test nterval may be necessary. 1 Shall be determned applcaton dependent. Step Acton 1 If necessary remove protectve equpment (splashguard, etc.).check f external blockage of gas/vapor path nto the sensng chamber exsts, eg. debrs, trash, snow, mud, external equpment, etc. 2 Remove such mpedments should they exst. Step Acton 3 Check the status LEDs/Dsplay 6.3 Gas Response Proof Test Gas response test 1 Gas response test 1 conssts of the followng steps, as descrbed n Table 1 Gas response test 1. Table 1 Gas response test 1 Step Acton 1 Bypass the safety PLC or take other approprate acton to avod a false trp (.e nhbt alarms) 2 Apply an adequate gas concentraton to reach the desred alarm value(s) (A1, A2), n order to verfy that: Confguraton 4 to 20 ma: The analog output current s equal to appled gas concentraton wthn an acceptable, applcaton-specfc tolerance. Confguraton Relay: The correspondng Alarm relay wll be de-energzed. Confguraton Profsafe: The measured value s equal to appled gas concentraton wthn an acceptable, applcaton-specfc tolerance. Ths tests for complance voltage problems such as a low loop power supply voltage or ncreased wrng resstance. Ths also tests for other possble falures. The relay reacton s confguraton-dependent. Alarm acknowledgment could be requred after the gas concentraton has reached a non alarm concentraton to reset the alarm state. 3 Repeat step 2 for every alarm value. 4 Restore the loop to full operaton 5 Remove the bypass from the safety PLC or otherwse restore normal operaton Ths test wll detect approxmately 50% of possble dangerous undetected (du) falures n the transmtter Gas response test 2 Gas response test 2 conssts of the followng steps, as descrbed n Table 2 Gas response test 2. Table 2 Gas response test 2 Step Acton 1 Bypass the safety PLC or take other approprate acton to avod a false trp 2 Perform a two-pont calbraton of the transmtter ( Zero and Span calbraton ) 3 Perform Proof Test 1 4 Restore the loop to full operaton 5 Remove the bypass from the safety PLC or otherwse restore normal operaton Ths test wll detect more than 90 % of possble du falures n the transmtter. 8 Safety Manual

9 Proof test 6.4 Test of the 4 to 20 ma output Test of the 4 to 20 ma output wll check the correct settng of the 4 to 20 ma output. Step Acton 1 Bypass the safety PLC or take other approprate acton to avod a false trp 2 Send a command to the transmtter to set the output current above the desred alarm value to verfy that the analog current reaches that value. 3 Send a command to the transmtter to go above the low alarm current output and verfy that the analog current reaches that value. 4 Restore the loop to full operaton 5 Remove the bypass from the safety PLC or otherwse restore normal operaton 6.5 Test of the relay outputs Test of the relay output wll check the correct functon of the relay outputs. Step Acton 1 Bypass the safety PLC or take other approprate acton to avod a false trp 2 Check the A1 relay by usng the test functon. 3 Check the A2 relay by usng the test functon. 4 Check the Fault relay by usng the test functon. 5 Restore the loop to full operaton 6 Remove the bypass from the safety PLC or otherwse restore normal operaton Safety Manual 9

10 Safety relevant parameters 7 Safety relevant parameters Parameter Gas settngs Measured gas Confrmaton Screen Gas Selected measured gas (e.g. Methane ) LEL category Category Three categores avalable 1: NIOSH, 2: IEC, 3: PTB Measured gas unt Unt Selected gas unt (e.g. %LEL ) Range Range Measurement value whch leads to an output 20 ma sgnal. LEL of measured gas Capture lmts Capture value Calbraton gas Calbraton gas concentraton LEL Gas LEL gas default Negatve capture Postve capture Capture offset Calbraton gas Calbraton unt LEL cal. gas Not lsted Sensor test Gas concentraton n Vol.-% where the Lower Exploson Lmt (LEL) s 100 % dependng on natonal or regonal regulatons. Default gas concentraton n Vol.-% where the Lower Exploson Lmt (LEL) s 100 % dependng on natonal or regonal regulatons. Clampng of measurements n range of the capture offset value + postve/negatve capture for both dsplay and current output. Concentraton, where the capture value s actve. Smoothng of measurements close to the capture offset value for both dsplay and current output. Selected calbraton gas (e.g. Methane ). Selected unt for calbraton gas concentraton (e.g. Vol.- % ). Calbraton gas LEL converson factor. Concentraton of calbraton gas. The user has to check the parameter aganst labellng of the calbraton gas cylnder. Enables and dsables the sensor selftest of the electrochemcal sensor. Must be actvated for SIL applcatons. Parameter Confrmaton Screen Sensorlock Sensor lock If Sensor lock actvated, the Polytron 8000 checks a replaced sensor aganst the prevous nstalled sensor. For Polytron 8000 a dfferent sensor part number wll be rejected. For Polytron 8700 a PIR 7000 transmtter wth a dfferent wavelength wll be rejected f Sensor lock s actvated. Relays Alarm enable/ dsable Alarm concentraton Hysteress Alarm mode Alarms A1 alarm A2 alarm A1 hysteress A2 hysteress A1 latchng A2 latchng A1 drecton A2 drecton A1 acknowledge A2 acknowledge A1 relay A2 relay When Alarms are set to dsabled, the alarm logc s dsabled. Gas concentraton n confgured unt, where the alarm wll be actvated. Concentraton bandwdth, where the alarm s vald after t has been actvated. Latchng not latchng: In non-latchng mode, the alarm status clears f the gas concentraton does not meet the alarm condton anymore. Rsng fallng: Confgurng whether the alarm should be trggered by a rsng or fallng gas concentraton. Acknowledgeable not acknowledgeable: In Acknowledgeable confguraton, the alarm relay can be reset, before alarm condtons clear. Normally energzed energzed: Normally energzed means, the relay col s energzed f the alarm condton s not met. Due to ths, a power fal wll lead to an alarm. 10 Safety Manual

11 Safety relevant parameters WARNING The end user must ensure that the capture value s below the alarm value. CAUTION Correct parameterzaton must be checked by a gas proof test. Default confguraton parameter are devce and sensor dependent. Refer to the Instructon for Use and sensor datasheet for further nformaton. Safety Manual 11

12 Condtons of use 8 Condtons of use 8.1 General To ensure overall system performance and effectveness, the selecton of an nstallaton ste for the transmtter s the most mportant factor. Consderable thought must be gven to every detal of nstallaton, partcularly: The local, state, federal codes and requrements that govern the nstallaton of gas montorng equpment. The electrcal codes that govern the routng and connecton of electrcal power and sgnal cables to gas montorng equpment. For non-condut nstallatons, an approved cable gland (See Secton 8.1, Approvals) must be used (e.g. Hawke A501/421/A/¾ NPT or equvalent). It mght be necessary to connect the sheld of the cable to the cable gland and to the controller n order to mprove RFI mmunty. The full range of envronmental condtons to whch the transmtters wll be exposed to. The physcal data of the gas or vapor to be detected. The specfcs of the applcaton (e.g. possble leaks, ar movement/draft, etc.). The degree of accessblty requred for mantenance purposes. The types of optonal and accessory equpment that wll be used wth the system. Any other lmtng factors or regulatons that would affect system performance or nstallatons. Only properly traned personnel may use and servce ths equpment. For avalable tranngs contact DrägerServce. 8.4 Proof tests 8.5 Flters Flters and chemcal converters requred for the safety functon shall be checked frequently. The test nterval depends on the applcaton and the envronmental condtons. CAUTION Proof tests shall be performed at regular ntervals. The proof test nterval shall be determned wth respect to the applcaton. WARNING Installaton of flters and chemcal converters may affect senstvty, gas response tme and/or cross senstvty. Flters may ncrease the gas response tme and therefore the tme to alarm. Flters have a lmted capacty and must be exchanged. The exchange nterval s applcaton-dependent. For EN5042 complance, the test nterval must not exceed 1 week 8.6 Relays 8.2 Access restrctons CAUTION The end user must ensure, that only personnel qualfed for calbraton may know the password to unlock the Polytron 8XX0 for calbraton The end user must ensure that only personnel qualfed for parameterzaton know the password to unlock the devce for parameterzaton. CAUTION The relays must be externally fused wth a 3 A fuse and operated normally energzed. For combustble applcatons, an alarm set pont 40 %LEL s recommended. The fault relay ndcates the specal state fault only. Other specal states should be montored va the 4 to 20 ma output. 8.3 SIL actvaton to 20 ma output CAUTION SIL actvaton of the Polytron 8XX0 must be set to enabled for use n safety applcatons. CAUTION The user must ensure that the specal states are confgured below 2 ma. The analog offset correcton of the 4 to 20 ma output s lmted ±0.1 ma, f SIL s actvated. 12 Safety Manual

13 Condtons of use 8.8 Polytron / Polytron 8000 The PIR 7000 may not be confgured standalone. 8.9 Polytron 8720 The PIR 7200 may not be confgured standalone Polytron 8200 DD Posonng substances Certan substances n the atmosphere to be montored can mpar the senstvty of the catalytc bead sensor. The followng are known at present: 1. Polymerzng substances such as ethylene oxde, acrylontrle, butadene, styrene. 2. Catalyst posons such as sulphur and phosphorous compounds, halogenated hydrocarbons, slcon compounds and metal vapours. WARNING Refer to the applcable sensor datasheet for detaled nformaton and constrants n safety related applcatons. Contact Dräger to ensure sutablty of the electrochemcal sensor n your specfc safety related applcaton. CAUTION Dongle wth functonalty sensor test must be nstalled. Sensor test must be enabled. Sensor lock must be enabled. Confgured range must be sensor default range. Exchange of sensor must be done va menu change sensor. Toxc substances Certan substances n the atmosphere to be montored can mpar the senstvty of the EC sensor. WARNING The end user must ensure that no posonng substances n the applcaton exst Requred O 2 concentraton Catalytc bead sensors requre a mnmum oxygen concentraton to work properly. WARNING An O 2 concentraton 12 Vol.-% s requred. Safety Manual 13

14 Safety functons 9 Safety functons 9.1 General The gas detector Polytron 8XX0 shall montor gas concentratons of combustble or toxc gases and vapors or CO 2 or O 2 n the ambent ar by usng dfferent sensor technologes and set the outputs based on ths montorng. The outputs conssts of 1 A 4 to 20 ma output that reflects the gas concentraton where 4 ma represents 0 % of range 20 ma represents 100 % of range 2 2 alarm relays wth confgurable alarms. The relay wll be swtched when gas concentraton exceeds the confgured threshold value. 1 fault relay 9.2 Safety ntegrty level 9.3 Safety accuracy Fal-Safe State 4 to 20 ma confguraton: The fal safe state s defned as the analog output wll be n the falure nformaton range accordng to Namur NE43. Fal Safe State Relay: The fal safe state s defned as settng the Fault relay to the de-energzed state. The fault relay must be normally energzed. Defnton Fal Dangerous: Falure that does not respond to a demand from the process (.e. beng unable to go to the defned fal-safe state) or devates the output measurement value more than 20 % of full scale. The devaton between measured value and true concentraton can exceed above errors, dependng on applcaton condtons. 9.4 Falure rates Assumptons The followng assumptons have been made durng the Falure Modes, Effects, and Dagnostc Analyss (FMEDA) of the gas transmtters Polytron /340, Polytron 8720, Polytron 8200 DD and Polytron Falure rates are constant, wear out mechansms are not ncluded. Propagaton of falures s not relevant. Falures durng parameterzaton are not consdered. Suffcent tests are performed pror to shpment to verfy the absence of vendor and/or manufacturng defects that prevent proper operaton of specfed functonalty to product specfcatons or cause operaton dfferent from the desgn analyzed. Materals are compatble wth process condtons. The nstrument s locked aganst unntended operaton/ modfcaton. External power supply falure rates are not ncluded. The mean tme to restoraton (MTTR) after a safe falure s 8 hours. The test tme of a connected safety PLC to react on a dangerous detected falure and brng the process to the safe state s 1 hour. The 4 to 20 ma output sgnal s fed to a SIL 2 complant analogue nput board of a safety PLC. The lsted falure rates are vald for operatng stress condtons typcal of an ndustral envronment smlar to IEC class C (sheltered locaton) wth temperature lmts wthn the manufacturer s ratng and an average temperature over a long perod of tme of 40 C (25 C ambent temperature plus nternal self heatng). For a hgher average temperature of 60 C, the falure rates should be multpled wth an experence-based factor of 2.5. A smlar multpler should be used f frequent temperature fluctuaton (daly fluctuaton of > 15 C) must be assumed. Humdty levels are assumed wthn manufacturer s ratng. Only the descrbed versons are used for safety applcatons. The applcaton program n the safety logc solver s confgured accordng to NAMUR NE43 to detect underrange and over-range falures and does not automatcally trp on these falures; therefore these falures have been classfed as dangerous detected falures. General necessary gas detecton tests have successfully been passed Useful lfetme Although a constant falure rate s assumed by the probablstc estmaton method, ths only apples provded that the useful lfetme of components s not exceeded. Beyond ther useful lfetme the result of the probablstc calculaton method s therefore meanngless, as the probablty of falure sgnfcantly ncreases wth tme. The useful lfetme vares and s hghly dependent on the component tself and other factors, ncludng but not lmted to ts operatng frequency and condtons temperature n partcular. Ths assumpton of a constant falure rate s based on the bathtub curve, whch shows the typcal behavour for the electronc components. Therefore t s obvous that the PFDAVG calculaton s only vald for components whch have ths constant doman and that the valdty of the calculaton s lmted to the useful lfetme of each component. The experence-based useful lfetme s usually between 8 and 12 years. 14 Safety Manual

15 Safety functons 9.5 Polytron / to 20 ma current output The entre vald measurement range for the output sgnal s between mn. 3.8 ma and max ma. Fault, mantenance and beam block warnng sgnal may be confgured as follows. Current [ma] Meanng < 1.2 Fault Yes 3.4 Mantenance sgnal Yes 2 Beam block warnng Yes > 21 Defect n analogue nterface --- Confgurable ( ma) Operaton n current snk operaton Falure category Falure rates (n FIT) λ SD Fal safe detected 0 λ SU Fal safe undetected 1 0 λ DD Fal dangerous detected 1130 λ DU Fal dangerous undetected 63 λ AU Fal annuncaton undetected 17 Safe falure fracton (SFF) 94.7 % DC D 94.7 % PFD AVG (T[Proof] = 1 year) 5.52E-04 For detaled nformaton see Instructon for Use. 1 λ SU has been added λ DD because of fal low behavour n current snk or current source mode operaton. Parameters related to the above safety functon Dagnostc test nterval 24 h Hardware Fault Tolerance (HFT) 0 Component type Type B SIL capablty SIL 2 Descrpton of the safe state Confgured alarm 3,6 ma Archtecture 1oo1 MTBF 56 years Useful lfetme (maxmum, see 9.4.2) 10 years Operaton n current source mode Falure category Falure rates (n FIT) λ SD Fal safe detected 0 λ SU Fal safe undetected 1 0 λ DD Fal dangerous detected 1137 λ DU Fal dangerous undetected 65 λ AU Fal annuncaton undetected 17 Safe falure fracton (SFF) 94.6 % DC D 94.6 % PFD AVG (T[Proof] = 1 year) 5.70E-04 1 λ SU has been added λ DD because of fal low behavour n current snk or current source mode operaton Relay output The relay output conssts of a Fault, an A1 and an A2 relay. A devce error wll be ndcated by swtchng the fault relay. The Alarm relays may be confgured applcaton dependent. Default Meanng Confgurable Fault A fault has been No detected. A1 Confgured A1 alarm condtons have been detected. Yes A2 Confgured A2 alarm condtons are detected. Yes For detaled nformaton see chapter 7, 8.6 and Instructon for Use. Parameters related to the above safety functon Dagnostc test nterval 24 h Hardware Fault Tolerance (HFT) 0 Component type Type B SIL capablty SIL 2 Descrpton of the safe state Confgured alarm 3,6 ma Archtecture 1oo1 MTBF 53 years Useful lfetme (maxmum, see 9.4.2) 10 years Safety Manual 15

16 Safety functons Falure rate Falure category Falure rates (n FIT) λ SD Fal safe detected 0 λ SU Fal safe undetected 242 λ DD Fal dangerous detected 964 λ DU Fal dangerous undetected 105 λ AU Fal annuncaton undetected 41 Safe falure fracton (SFF) 92.0 % DC D 90.1 % PFD AVG (T[Proof] = 1 year) 8.99E Safety Manual

17 Safety functons 9.6 Polytron to 20 ma current output The entre vald measurement range for the output sgnal s between mn. 3.8 ma and max ma. Fault, mantenance and beam block warnng sgnal may be confgured as follows. Current [ma] Meanng < 1.2 Fault Yes 3.4 Mantenance sgnal Yes 2 Beam block warnng Yes > 21 Defect n analogue --- nterface Parameters related to the above safety functon Operaton n current source mode Confgurable ( ma) For detaled nformaton see Instructon for Use. Dagnostc test nterval 24 h Hardware Fault Tolerance 0 (HFT) Component type Type B SIL capablty SIL 2 Descrpton of the safe state Confgured alarm 3,6 ma Archtecture 1oo1 MTBF 61 years Useful lfetme (maxmum, 10 years see Falure category Falure rates (n FIT) λ SD Fal safe detected 0 λ SU Fal safe undetected 1 0 λ DD Fal dangerous detected 1137 λ DU Fal dangerous undetected 65 λ AU Fal annuncaton undetected 17 Safe falure fracton (SFF) 94.6 % DC D 94.6 % PFD AVG (T[Proof] = 1 year) 5.70E-04 1 λ SU has been added λ DD because of fal low behavour n current snk or current source mode operaton. Operaton n current snk operaton Falure category Falure rates (n FIT) λ SD Fal safe detected 0 λ SU Fal safe undetected 1 0 λ DD Fal dangerous detected 1130 λ DU Fal dangerous undetected 63 λ AU Fal annuncaton undetected 17 Safe falure fracton (SFF) 94.7 % DC D 94.7 % PFD AVG (T[Proof] = 1 year) 5.52E-04 1 λ SU has been added λ DD because of fal low behavour n current snk or current source mode operaton Relay output The relay output conssts of a Fault, an A1 and an A2 relay. A devce error wll be ndcated by swtchng the fault relay. The Alarm relays may be confgured applcaton dependent. Relay Meanng Confgurable Fault A fault has been No detected. A1 Confgured A1 alarm condtons have been detected. Yes A2 Confgured A2 alarm condtons are detected. Yes For detaled nformaton see chapter 7, 8.6 and Instructon for Use. Parameters related to the above safety functon Dagnostc test nterval 24 h Hardware Fault Tolerance 0 (HFT) Component type Type B SIL capablty SIL 2 Descrpton of the safe state Confgured alarm 3,6 ma Archtecture 1oo1 MTBF 53 years Useful lfetme (maxmum, 10 years see 9.4.2) Safety Manual 17

18 Safety functons Falure rate Falure category Falure rates (n FIT) λ SD Fal safe detected 0 λ SU Fal safe undetected 242 λ DD Fal dangerous detected 964 λ DU Fal dangerous undetected 105 λ AU Fal annuncaton undetected 41 Safe falure fracton (SFF) 92.0 % DC D 90.1 % PFD AVG (T[Proof] = 1 year) 8.99E Safety Manual

19 Safety functons 9.7 Polytron 8200 DD to 20 ma current output The entre vald measurement range for the output sgnal s between mn. 3.8 ma and max ma. Fault, mantenance and beam block warnng sgnal may be confgured as follows. Current [ma] Meanng < 1.2 Fault Yes 3.4 Mantenance sgnal Yes > 21 Defect n analogue --- nterface Confgurable ( ma) Operaton n current snk operaton Falure category Falure rates (n FIT) λ SD Fal safe detected 0 λ SU Fal safe undetected 1 0 λ DD Fal dangerous detected 3294 λ DU Fal dangerous undetected 209 λ AU Fal annuncaton undetected 14 Safe falure fracton (SFF) 94.0 % DC D 94.0 % For detaled nformaton see Instructon for Use. Parameters related to the above safety functon Dagnostc test nterval 24 h Hardware Fault Tolerance 0 (HFT Component type Type B SIL capablty SIL 2 Descrpton of the safe state Confgured alarm 3,6 ma Archtecture 1oo1 MTBF 29 years Useful lfetme (maxmum, 10 years see 9.4.2) Operaton n current source mode PFD AVG (T[Proof] = 1 year) 1.82E-03 1 λ SU has been added λ DD because of fal low behavour n current snk or current source mode operaton Relay output The relay output conssts of a Fault, an A1 and an A2 relay. A devce error wll be ndcated by swtchng the fault relay. The Alarm relays may be confgured applcaton dependent. Default Meanng Confgurable Fault A fault has been No detected. A1 Confgured A1 alarm condtons have been detected. Yes A2 Confgured A2 alarm condtons are detected. Yes Falure category Falure rates (n FIT) λ SD Fal safe detected 0 λ SU Fal safe undetected 1 0 λ DD Fal dangerous detected 3301 λ DU Fal dangerous undetected 211 λ AU Fal annuncaton undetected 14 Safe falure fracton (SFF) 94.0 % DC D 94.0 % PFD AVG (T[Proof] = 1 year) 1.84E-03 1 λ SU has been added λ DD because of fal low behavour n current snk or current source mode operaton. For detaled nformaton see chapter 7, 8.6 and Instructon for Use. Parameters related to the above safety functon Dagnostc test nterval 24 h Hardware Fault Tolerance 0 (HFT) Component type Type B SIL capablty SIL 2 Descrpton of the safe state Confgured alarm 3,6 ma Archtecture 1oo1 MTBF 28 years Useful lfetme (maxmum, 10 years see 9.4.2) Safety Manual 19

20 Safety functons Falure rate Falure category Falure rates (n FIT) λ SD Fal safe detected 0 λ SU Fal safe undetected 841 λ DD Fal dangerous detected 2526 λ DU Fal dangerous undetected 251 λ AU Fal annuncaton undetected 37 Safe falure fracton (SFF) 93.1 % DC D 91.0 % PFD AVG (T[Proof] = 1 year) 2.15E Safety Manual

21 Safety functons 9.8 Polytron to 20 ma current output The entre vald measurement range for the output sgnal s between mn. 3.8 ma and max ma. Fault, mantenance, and Beamblock warnng sgnal may be confgured as follows. Current [ma] Meanng < 1.2 Fault Yes 3.4 Mantenance sgnal Yes > 21 Defect n analogue --- nterface Confgurable ( ma) Operaton n current snk operaton Falure category Falure rates (n FIT) λ SD Fal safe detected 0 λ SU Fal safe undetected 1 0 λ DD Fal dangerous detected 1434 λ DU Fal dangerous undetected 101 λ AU Fal annuncaton undetected 15 Safe falure fracton (SFF) 93.4 % DC D 93.4 % For detaled nformaton see Instructon for Use. PFD AVG (T[Proof] = 1 year) 8.76E-04 1 λ SU has been added λ DD because of fal low behavour n current snk or current source mode operaton. Parameters related to the above safety functon Dagnostc test nterval 24 h Hardware Fault Tolerance 0 (HFT) Component type Type B SIL capablty SIL 2 Descrpton of the safe state Confgured alarm 3,6 ma Archtecture 1oo1 MTBF 53 years Useful lfetme (maxmum, see 10 years 9.4.2) Operaton n current source mode Falure category Falure rates (n FIT) λ SD Fal safe detected 0 λ SU Fal safe undetected 1 0 λ DD Fal dangerous detected 1441 λ DU Fal dangerous undetected 103 λ AU Fal annuncaton undetected 15 Safe falure fracton (SFF) 93.3 % DC D 93.3 % PFD AVG (T[Proof] = 1 year) 8.94E-04 1 λ SU has been added λ DD because of fal low behavour n current snk or current source mode operaton Relay output The relay output conssts of a Fault, an A1 and an A2 relay. A devce error wll be ndcated by swtchng the fault relay. The Alarm relays may be confgured applcaton dependent. Default Meanng Confgurable Fault A fault has been No detected. A1 Confgured A1 alarm condtons have been detected. Yes A2 Confgured A2 alarm condtons are detected. Yes For detaled nformaton see chapter 7, 8.6 and Instructon for Use. Parameters related to the above safety functon Dagnostc test nterval 24 h Hardware Fault Tolerance 0 (HFT) Component type Type B SIL capablty SIL 2 Descrpton of the safe state Confgured alarm 3,6 ma Archtecture 1oo1 MTBF 50 years Useful lfetme (maxmum, see 10 years 9.4.2) Safety Manual 21

22 Reference documents Falure rate 10 Reference documents Falure category Falure rates (n FIT) λ SD Fal safe detected 0 λ SU Fal safe undetected 461 λ DD Fal dangerous detected 1046 λ DU Fal dangerous undetected 143 λ AU Fal annuncaton undetected 38 Document Instructons for Use (en) Dräger Polytron 8700/8720 Instructons for Use (en) Dräger Polytron 8200/8310 Instructons for Use (en) Dräger Polytron 8000 Order no Safe falure fracton (SFF) 91.3 % DC D 88.0 % PFD AVG (T[Proof] = 1 year) 1.22E Safety Manual

23 Lst of Abbrevatons 11 Lst of Abbrevatons AU, Annuncaton An annuncaton falure (AU) s defned undetected (falure) as a falure that does not drectly mpact safety but does mpact the ablty to detect a future fault (such as a fault n a dagnostc crcut). For the calculaton of the SFF t s treated as no effect falure and has not been taken nto account. DC D Dagnostc Coverage of dangerous falures DC D = λ DD / (λ DD + λ DU ) DU Dangerous Undetected (falure) FMEDA Falure Modes, Effects, and Dagnostc Analyss HART Hghway Addressable Remote Transducer HFT Hardware Fault Tolerance IR Infrared Low demand mode Mode, where the frequency of demands for operaton made on a safety-related system s no greater than one per year and no greater than twce the proof test frequency. MTBF Mean tme Between Falure MTTR Mean tme To Restoraton PFD Probablty of Falure on Demand PFH Probablty of dangerous Falure per Hour The term Probablty s msleadng, as IEC defnes a Rate. PLC Programmable Logc Controller SFF Safe Falure Fracton; summarses the fracton of falures, whch lead to a safe state and the fracton of falures whch wll be detected by dagnostc measures and lead to a defned safety acton. SFF = (λ S + λ DD )/ (λ S + λ D ) λ S = λ SD + λ SU λ D = λ DD + λ DU SIL SIS Type B component T[Proof] Safety Integrty Level Safety Instrumented System Complex component (usng mcro controllers or programmable logc); for detals see of IEC Proof test nterval Safety Manual 23

24 Lst of Abbrevatons 24 Safety Manual

25 Lst of Abbrevatons Safety Manual 25

26 Lst of Abbrevatons 26 Safety Manual

27

28 Dräger Safety AG & Co. KGaA Revalstraße Lübeck, Germany Tel Fax Manufacturng Locaton: Draeger Safety, Inc. 101 Technology Drve Pttsburgh, PA , USA Phone Fax TM Dräger Safety AG & Co. KGaA Edton 02 - February 2012 (Edton 01 - September 2011) Subject to alteraton