Reliability & Risk Assessment

FSM-002 - AQ, DQ, IQ, SLR, SRA, SRX and VSD – VALVE POSITION MONITOR
FUNCTIONAL SAFETY MANUAL
1. Scope
The product is a valve position monitor comprising at least one switch, sensor or transmitter in an enclosure
that is activated by a shaft/cam assembly when a defined valve position is achieved by tracking the
movement of the valve via a mechanical linkage system. Number 2 to 6 x mechanical switches, hermetically
sealed reed switches or inductive proximity sensors or Number 1 to 2 continuous position transmitter can be
utilised to provide feedback.
Hazardous events will include failure of a switch/sensor/transmitter connected to the plant SIS to report valve
position such that the SIS is compromised.
2. Safety-related Functions
2.1 Reporting valve position to Plant SIS in situations where the limit switch or transmitter feedback loop is
integral to SIS.
2.2 The electrical product life is 200,000 operations for Mechanical switches, 1,000,000 operations for Reed
Switches or Potentiometer based transmitters, and at least 2.000,000 operations for Solid State sensors and
Transmitters. The electrical life of a Mechanical switch can seriously deteriorate if installed in a demanding
environment.
The mechanical life of the product will depend on the installed environment and the maintenance strategy
employed. The maintenance frequency should be determined by the product operator based on the application into
which the product is installed.
Special Note on Reed Switches: Where reed switches (particularly low power, rhodium contact type) are installed
at the end of long cable runs (typically above 50m), precautions should be taken to ensure cable capacitance does
not induce premature switch failure. Consult Imtex for further information.
3. Interfaces
Valve Position Monitor is mounted to the host valve/actuator using an interface kit. Field wiring is brought into the
monitor via a suitable cable gland and terminated in a terminal block within the monitor.
Interfaces should be fitted using recognised industrial practices and be in accordance with the Installation,
Operation and Maintenance Instructions for the individual Valve Position Monitor.
3.1 Inputs/Outputs
 Drive shaft, with cam(s) as required, connected directly or via a coupler to the valve/actuator to be
monitored.
 Field wiring connected to SIS
4. General
The monitor should be fitted using a suitable mounting interface that ensure proper alignment of the monitor
drive shaft.
Monitors are intended for fitting to assemblies operating with a frequency of no greater than 15 cycles per
minute.
The Switches/Sensors/Transmitter within the Valve Position Monitor should respond to a change of status
within 0.3sec. Transmitters utilising the PR Transmitter should respond within 1s.
FSM-002 FS Manual – VPM Version 2.12

March 2016
5. Environment
Operating Environment should be in accordance the Installation, Operation and Maintenance Instructions for
the individual Valve Position Monitor.
6. Internal Diagnostics and Proof Testing
A proportion of 'Failures to Signal’ by a given switch will be communicated to the SIS by reference to the
secondary switch/sensor within the monitor. A 'Failure to Signal' by a transmitter will be communicated to the
SIS by loss of signal or the transmitter moving to a fixed, out of normal range signal.
Where the Monitor has not operated for a period of one year or longer, it is recommended that a test be run to
verify operability.
7. Start-Up Requirements
Following a failure to report, the failed component should be replaced by a qualified operator.
8. Failure Rates
The details below are taken from Technis Report T319.
In respect of the perceived failure modes:
Following a valid host valve movement, either of the output signalling devices failing to achieve a
specified condition.
Following a valid host valve movement, one of the output signalling devices failing to achieve a specified
condition.
(Potentiometer) Following a host valve movement >10% of current position, failing to reflect the change in
a 4-20mA signal (noting that <4mA and >20mA outputs are utilised as revealed failure scenarios).
(Non-contact sensor) Failure to report actual valve position to within 5% accuracy to the 4-20mA
transmitter output.

March 2016
The specific output failure mode conditions are identified in the following table.
VERSION FAILURE FAILURE RATE FAILURE RATE

per million hrs per million hrs
TOTAL HAZARDOUS
Microswitch Any one o/p 0.12 0.04
Output Normally open -
fail to close
Any one o/p 0.12 0.02
Normally closed -
fail to open
Either of 2 o/ps 0.43 0.13
Normally open -
fail to close
Either of 2 o/ps Normally 0.42 0.05
closed -
fail to open
Reed Switch Any one o/p 0.32 0.10

Normally open -
fail to close
Any one o/p 0.32 0.04
Normally closed -
fail to open
Normally open -
fail to close
Either of 2 o/ps Normally 0.63 0.07
closed -
fail to open
Inductive Any one o/p 0.07 0.016

Sensor Fails to change state
Fails to change state
Potentiometer and Fail to indicate >10% valve 1.2 0.95

4-20mA o/p movement
Potentiometer and Fail to indicate >10% valve 1.8 0.47
4-20mA o/p with movement
1oo2 duplicated
potentiometer
Non-contact Fail to indicate >5% position 0.23 0.19

Transmitter error
Non-contact Fail to indicate >5% position 0.47 0.019

Transmitter 1oo2 error
duplicated
These failure rates are for inclusion in a wider calculation of a safety function. They could be, however, sufficiently small as
to allow suitability for the use of these items in up to SIL 3 applications.

March 2016

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FSM-002 - AQ, DQ, IQ, SLR, SRA, SRX and VSD – VALVE POSITION MONITOR

FUNCTIONAL SAFETY MANUAL

FSM-002 FS Manual – VPM Version 2.12

6. Internal Diagnostics and Proof Testing

The details below are taken from Technis Report T319.

In respect of the perceived failure modes:

FSM-002 FS Manual – VPM Version 2.12

VERSION FAILURE FAILURE RATE FAILURE RATE

Reed Switch Any one o/p 0.32 0.10

Inductive Any one o/p 0.07 0.016

Potentiometer and Fail to indicate >10% valve 1.2 0.95

Non-contact Fail to indicate >5% position 0.23 0.19

Non-contact Fail to indicate >5% position 0.47 0.019

FSM-002 FS Manual – VPM Version 2.12

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