Emerson Fisher 1052 User guide

www.Fisher.com

Safety manual for Fisher™1052 Actuators

Purpose

This safety manual provides information necessary to design, install, verify and maintain a Safety Instrumented

Function (SIF) utilizing the Fisher 1052 spring and diaphragm rotary actuator.

WARNING

This instruction manual supplement is not intended to be used as a stand-alone document. It must be used in conjunction

with the following manuals:

Fisher 1051 and 1052 Style F and G Size 40, 60, and 70 Rotary Actuators Instruction Manual (D100319X012)

Fisher 1052 Size 20 Diaphragm Rotary Actuator with F and G Mounting Adaptation Instruction Manual (D100322X012)

Fisher 1051 and 1052 Size 33 Diaphragm Rotary Actuators Instruction Manual (D101322X012)

Failure to use this instruction manual supplement in conjunction with the above referenced manual could result in personal

injury or property damage. If you have any questions regarding these instructions or need assistance in obtaining any of

these documents, contact your Emerson sales office or Local Business Partner.

Introduction

This manual provides necessary requirements for meeting the IEC 61508 or IEC 61511 functional safety standards.

Figure 1. Fisher 1052 Actuator

W8172‐3

Size 33

W8508-3

Size 60

1052 Actuator

October 2017

Instruction Manual Supplement

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Instruction Manual Supplement

D103790X012

1052 Actuator

October 2017

Terms and Abbreviations

Safety: Freedom from unacceptable risk of harm.

Functional Safety: The ability of a system to carry out the actions necessary to achieve or to maintain a defined safe

state for the equipment / machinery / plant / apparatus under control of the system.

Basic Safety: The equipment must be designed and manufactured such that it protects against risk of injury to persons

by electrical shock and other hazards and against resulting fire and explosion. The protection must be effective under

all conditions of the nominal operation and under single fault condition.

Safety Assessment: The investigation to arrive at a judgment  based on the facts  of the safety achieved by

safetyrelated systems.

FailSafe State: State where valve actuator is deenergized and spring is extended.

Fail Safe: Failure that causes the valve to go to the defined failsafe state without a demand from the process.

Fail Dangerous: Failure that does not respond to a demand from the process (i.e. being unable to go to the defined

failsafe state).

Fail Dangerous Undetected: Failure that is dangerous and that is not being diagnosed by automatic stroke testing.

Fail Dangerous Detected: Failure that is dangerous but is detected by automatic stroke testing.

Fail Annunciation Undetected: Failure that does not cause a false trip or prevent the safety function but does cause

loss of an automatic diagnostic and is not detected by another diagnostic.

Fail Annunciation Detected: Failure that does not cause a false trip or prevent the safety function but does cause loss of

an automatic diagnostic or false diagnostic indication.

Fail No Effect: Failure of a component that is part of the safety function but that has no effect on the safety function.

Low demand mode: Mode, where the frequency of demands for operation made on a safetyrelated system is no

greater than twice the proof test frequency.

Acronyms

FMEDA: Failure Modes, Effects and Diagnostic Analysis

HFT: Hardware Fault Tolerance

MOC: Management of Change. These are specific procedures often done when performing any work activities in

compliance with government regulatory authorities.

PFDAVG:Average Probability of Failure on Demand

SFF: Safe Failure Fraction, the fraction of the overall failure rate of a device that results in either a safe fault or a

diagnosed unsafe fault.

SIF: Safety Instrumented Function, a set of equipment intended to reduce the risk due to a specific hazard (a safety

loop).

SIL: Safety Integrity Level, discrete level (one out of a possible four) for specifying the safety integrity requirements of

the safety functions to be allocated to the E/E/PE safetyrelated systems where Safety Integrity Level 4 has the highest

level of safety integrity and Safety Integrity Level 1 has the lowest.

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SIS: Safety Instrumented System – Implementation of one or more Safety Instrumented Functions. A SIS is composed

of any combination of sensor(s), logic solver(s), and final element(s).

Related Literature

Hardware Documents:

Bulletin:

61.1:1052, Fisher 1051 and 10522 Diaphragm Rotary Actuators: D100089X012

Instruction Manual:

Fisher 1051 and 1052 Style F and G Size 40, 60, and 70 Rotary Actuators: D100319X012

Fisher 1052 Size 20 Diaphragm Rotary Actuator with F and G Mounting Adaptation: D100322X012

Fisher 1051 and 1052 Size 33 Diaphragm Rotary Actuators: D101322X012

Guidelines/References:

D Safety Integrity Level Selection – Systematic Methods Including Layer of Protection Analysis, ISBN 1556177771,

ISA

D Control System Safety Evaluation and Reliability, 2nd Edition, ISBN 1556176388, ISA

D Safety Instrumented Systems Verification, Practical Probabilistic Calculations, ISBN 1556179099, ISA

Reference Standards

Functional Safety

D IEC 61508: 2010 Functional safety of electrical/electronic/ programmable electronic safetyrelated systems

D ANSI/ISA 84.00.012004 (IEC 61511 Mod.) Functional Safety – Safety Instrumented Systems for the Process Industry

Sector

Product Description

The Fisher 1052 is a spring and diaphragm rotary actuator.

The 1052 actuator can be installed on rotaryshaft valve bodies for throttling or onoff applications. The actuator

linkage features a clamped shaft lever and a single pivot point to reduce lost motion between the actuator and the

valve.

The 1052 actuator delivers several operations and maintenance advantages. It has an inherent failsafe position on loss

of operating air. In contrast to piston style actuators that rely on oring seals, the doublesided diaphragm in the 1052

actuator provides a longer service life.

Powder paint coating is standard and offers an excellent corrosionresistant finish on all external steel and cast iron

parts.

The 1052 actuator is used with a rotary valve to control process fluids that can be used in a wide variety of applications.

They are typically used with other interface components (valve positioner or solenoid valve) to provide a final element

subsystem for a SIF.

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Designing a SIF Using a Fisher 1052 Actuator

Safety Function

When the 1052 actuator is deenergized, the actuator and valve shall move to its failsafe position. Depending on

which configuration is specified fail-closed or fail-open, the actuator will rotate the valve control element to close off

the flow path through the valve body or open the flow path through the valve body.

The 1052 actuator is intended to be part of final element subsystem as defined per IEC 61508 and the achieved SIL

level of the designed function must be verified by the designer.

Environmental limits

The designer of an SIF must check that the product is rated for use within the expected environmental limits. Refer to

the Fisher 1052 Diaphragm Rotary Actuator Product Bulletin for environmental limits.

Application limits

The 1052 actuator materials of construction are specified in the product bulletin. A range of materials are available for

various applications. The serial card will indicate what the materials of construction are for a specific actuator. It is

especially important that the designer check for material compatibility considering onsite chemical contaminants and

air supply conditions. If the 1052 actuator is used outside of the application limits or with incompatible materials, the

reliability data provided becomes invalid.

Diagnostic Response Time

A 1052 actuator does not perform any automatic diagnostic functions by itself and therefore it has no diagnostic

response time of its own. However, automatic diagnostics of the final control subsystem may be performed such as

Partial Valve Stroke Testing (PVST). This typically will exercise the actuator and valve over a small percentage of its

normal travel without adversely affecting the flow through the valve. If any failures of this PVST are automatically

detected and annunciated, the diagnostic response time will be the PVST interval time. The PVST must be performed

10 times more often than an expected demand in order for credit to be given for this test.

Design Verification

A detailed FMEDA report is available from Emerson. This report details all failure rates and failure modes as well as the

expected lifetime.

The achieved SIL of an entire SIF design must be verified by the designer via a calculation of PFDAVG considering

architecture, proof test interval, proof test effectiveness, any automatic diagnostics, average repair time and the

specific failure rates of all products included in the SIF. Each subsystem must be checked to assure compliance with

minimum HFT requirements.

When using a 1052 actuator in a redundant configuration, a common cause factor of at least 5% should be included in

the Safety Integrity calculations. This value is dependent on the level of common cause training and maintenance in

use at the end user's facility.

The failure rate data listed the FMEDA report is only valid for the useful lifetime of a 1052 actuator. The failure rates will

increase after this time period. Reliability calculations based on the data listed in the FMEDA report for mission times

beyond the useful lifetime may yield results that are too optimistic, i.e. the calculated Safety Integrity Level will not be

achieved.

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SIL Capability

Systematic Integrity

Figure 2. exida SIL 3 Capable

The product has met manufacturer design process requirements of SIL 3. These are intended to achieve sufficient

integrity against systematic errors of design by the manufacturer. A SIF designed with this product must not be used at

a SIL level higher than stated without “prior use” justification by the end user or diverse technology redundancy in the

design.

Random Integrity

The Fisher 1052 diaphragm rotary actuator is classified as Type A devices according to IEC 61508, having a hardware

fault tolerance of 0. The complete final element subsystem, with a 1052 actuator and rotary valve as the final control

element, will need to be evaluated to determine the Safe Failure Fraction of the subsystem. If the SFF for the entire

final element subsystem is between 60% and 90%, a design can meet SIL 2 @ HFT=0.

Safety Parameters

For detailed failure rate information refer to the Failure Modes, Effects and Diagnostic Analysis Report for the Fisher

1052 actuator.

Connection of the Fisher 1052 Actuator to the SIS Logic-solver

The final element subsystem (consisting of a positioner, 1052 actuator, and a rotary valve) is connected to the safety

rated logic solver which is actively performing the Safety Function as well as any automatic diagnostics designed to

diagnose potentially dangerous failures within the 1052 actuator, valve and any other final element components (i.e.

Partial Valve Stroke Test).

General Requirements

The system's response time shall be less than process safety time. The final control element subsystem needs to be

sized properly to assure that the response time is less than the required process safety time. The 1052 actuator will

move the valve to its safe state in less than the required SIF's safety time under the specified conditions.

All SIS components including the 1052 actuator must be operational before process startup.

The user shall verify that the 1052 actuator is suitable for use in safety applications.

Personnel performing maintenance and testing on the 1052 actuator and valve shall be competent to do so.

Results from the proof tests shall be recorded and reviewed periodically.

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The useful life of the 1052 actuator is discussed in the Failure Modes, Effects and Diagnostic Analysis Report for the

1052 actuator.

Installation and Commissioning

Installation

WARNING

To ensure safe and proper functioning of equipment, users of this document must carefully read all instructions, warnings,

and cautions in each applicable instruction manual.

The Fisher 1052 diaphragm rotary actuator must be installed per standard practices outlined in the instruction

manual.

The environment must be checked to verify that environmental conditions do not exceed the ratings.

The 1052 actuator must be accessible for physical inspection.

Physical Location and Placement

The 1052 actuator shall be accessible with sufficient room for the valve, actuator, pneumatic connections, any other

components of the final control element. Provisions shall be made to allow for manual proof testing.

Pneumatic piping to the actuator shall be kept as short and straight as possible to minimize the airflow restrictions and

potential clogging. Long or kinked pneumatic tubes may also increase the valve closure time.

The 1052 actuator shall be mounted in a low vibration environment. If excessive vibration can be expected special

precautions shall be taken to ensure the integrity of pneumatic connectors or the vibration should be reduced using

appropriate damping mounts.

Pneumatic Connections

Recommended piping for the inlet and outlet pneumatic connections to the 1052 actuator is stainless steel or PVC

tubing. The length of tubing between the 1052 actuator and the control device, such as a solenoid valve, shall be kept

as short as possible and free of kinks.

Only dry instrument air filtered to 50 micron level or better shall be used.

The process air pressure shall meet the requirements set forth in the installation manual.

The process air capacity shall be sufficient to move the valve within the required time.

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Operation and Maintenance

Suggested Proof Test

The objective of proof testing is to detect failures within a 1052 actuator that are not detected by any automatic

diagnostics of the system. Of main concern are undetected failures that prevent the Safety Instrumented Function

from performing its intended function.

The frequency of proof testing, or the proof test interval, is to be determined in reliability calculations for the Safety

Instrumented Functions for which a 1052 actuator is applied. The proof tests must be performed more frequently than

or as frequently as specified in the calculation in order to maintain the required Safety Integrity of the Safety

Instrumented Function.

The proof test shown in table 1 is recommended. The results of the proof test should be recorded and any failures that

are detected and that compromise functional safety should be reported to Emerson. The suggested proof test consists

of a full stroke of the 1052 actuator.

The person(s) performing the proof test of a 1052 actuator should be trained in SIS operations, including bypass

procedures, valve maintenance and company Management of Change procedures. No special tools are required.

Table 1. Recommended Full Stroke Proof Test

Step Action

1Bypass the safety function and take appropriate action to avoid a false trip.

2Interrupt or change the signal/supply to the 1052 actuator to force the actuator and valve to perform a full stroke

to the FailSafe state and confirm that the Safe State was achieved and within the correct time.

3Restore the supply/signal to the 1052 actuator and confirm that the normal operating state was achieved.

4Inspect the 1052 actuator and the other final control element components for any leaks, visible damage or contamination.

5Record the test results and any failures in your company's SIF inspection database.

6Remove the bypass and restore normal operation.

Repair and replacement

Repair procedures in the 1052 actuator instruction manual must be followed.

Manufacturer Notification

Any failures that are detected and that compromise functional safety should be reported to Emerson. Please contact

your Emerson sales office or Local Business Partner.

Status of the Document

Releases

Version History: (Version, Status, Date)

Instruction Manual Supplement

D103790X012

1052 Actuator

October 2017

Appendix A

Sample Startup Checklist

This appendix provides a sample Startup Checklist for a 1052 actuator. A Startup Checklist will provide guidance

during the final control elements employment.

Start-Up Checklist

The following checklist may be used as a guide to employ the 1052 actuator in a safety critical SIF compliant to

IEC61508.

# Activity Result Verified

By Date

Design

Target Safety Integrity Level and PFDAVG determined

Correct valve mode chosen (Failclosed, Failopen)

Design decision documented

Pneumatic compatibility and suitability verified

SIS logic solver requirements for valve tests defined and documented

Routing of pneumatic connections determined

SIS logic solver requirements for partial stroke tests defined and

documented

Design formally reviewed and suitability formally assessed

Implementation

Physical location appropriate

Pneumatic connections appropriate and according to applicable codes

SIS logic solver valve actuation test implemented

Maintenance instructions for proof test released

Verification and test plan released

Implementation formally reviewed and suitability formally assessed

Verification and Testing

Electrical connections verified and tested

Pneumatic connection verified and tested

SIS logic solver valve actuation test verified

Safety loop function verified

Safety loop timing measured

Bypass function tested

Verification and test results formally reviewed and suitability formally

assessed

Maintenance

Tubing blockage / partial blockage tested

Safety loop function tested

Emerson Automation Solutions

Marshalltown, Iowa 50158 USA

Sorocaba, 18087 Brazil

Cernay, 68700 France

Dubai, United Arab Emirates

Singapore 128461 Singapore

www.Fisher.com

The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not

to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are

governed by our terms and conditions, which are available upon request. We reserve the right to modify or improve the designs or specifications of such

products at any time without notice.

Fisher, Control-Disk, and Vee-Ball are marks owned by one of the companies in the Emerson Automation Solutions business unit of Emerson Electric Co.

Emerson Automation Solutions, Emerson, and the Emerson logo are trademarks and service marks of Emerson Electric Co. All other marks are the property

of their respective owners.

Neither Emerson, Emerson Automation Solutions, nor any of their affiliated entities assumes responsibility for the selection, use or maintenance

of any product. Responsibility for proper selection, use, and maintenance of any product remains solely with the purchaser and end user.

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