Det-Tronics SAFETY MANUAL Electrochemical Gas Detector GT3000 Series Includes Transmitter (GTX) with H2S or O2 Sensor Module (GTS)
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SAFETY MANUAL Electrochemical Gas Detector GT3000 Series Includes Transmitter (GTX) with H2S or O2 Sensor Module (GTS) Sensor Module (GTS) Transmitter (GTX) SAFETY CERTIFIED GT3000 Series Electrochemical Gas Detector This manual addresses the specific requirements and recommendations applicable to the proper installation, operation, and maintenance of all Safety-Certified (SIL‑Certified) GT3000 Electrochemical Gas Detector product versions. For complete information regarding system overview, performance, installation, operation, maintenance and specifications of the GT3000 Series, refer to instruction manual 95-8616. QUALITY POLICY STATEMENT All quality assurance control measures necessary for safety management as specified in IEC 61508 Part 1 have been implemented. The quality management system of Det-Tronics is based on the requirements of EN ISO 9001 and ANSI/ASQC Q9001 through the application of the United Technologies Company Achieving Competitive Excellence (ACE) program. In addition, the Quality Management System complies with the European ATEX Directive requirements per EN 13980, the International Electrotechnical Commission requirements per OD005/V2, and the supervised testing requirements per ISO 17025. 3.1 © Detector Electronics Corporation 2015 Detector (GT3000) SAFETY MESSAGES Procedures and instructions in this section may require special precautions to ensure the safety of personnel performing the operations. Information that raises potential safety issues is indicated by the word “Warning”. Always read and understand these safety messages. WARNING The GT3000 Electrochemical Gas Detector is intended for use in hazardous environments that may include explosive levels of flammable gases and vapors. This product must be properly installed, operated and maintained. Improper installation or use could result in an explosion or fire resulting in death or serious injury. • Do not remove the cover of a junction box in explosive environments when device power is on and circuits are live. • Device must be properly installed to meet hazardous area explosion-proof/non‑incendive and intrinsic safety requirements. Rev: 7/15 95-8685 DESIGN VALID INPUT RANGE The GT3000 Electrochemical Gas Detector is an intelligent stand-alone industrial gas detector, designed to provide continuous monitoring of the atmosphere for hazardous gas leaks or oxygen depletion. The GT3000 Gas Detector consists of a replaceable sensor module (Model GTS) connected to a transmitter module (Model GTX). The GT3000 is a 2-wire device that generates a 4-20 mA output signal with HART communication that is proportional to the concentration of the target gas. The GT3000 is compatible with FlexVu® Model UD10 and UD20 Universal Display Units, as well as other devices that are able to monitor a linear 4-20 mA dc signal. All alarm functions are provided by the monitoring device. GT3000 fault annunciation is provided on the 4-20 mA signal output loop by signaling to a specific mA current output level. The receiving device must be programmed to indicate a fault condition when current levels reach under-current of 3.6 mA or less or overcurrent of 21 mA or more. NOTE The GT3000 analog signal is not safety-rated during detector warm-up or calibration mode. Alternative means should be used at the job site to ensure facility safety during these activities. DIAGNOSTIC RESPONSE TIME The GT3000 is classified as Type B smart element according to IEC61508. The GT3000 contains selfdiagnostics and sends the current output to a specified failure state upon internal detection of a failure (see GT3000 instruction manual for details). Safety-Certification of the GT3000 Electrochemical Gas Detector includes: The GT3000 will perform all critical diagnostic functions within one hour, worst case diagnostic detection time. CERTIFICATION The GT3000 Safety-Certified version is certified by exida® to IEC61508 for single input use in low demand, SIL 2 Safety Instrumented Systems. Series • the 4-20 mA output of the GTX in combination with H2S or O2 GTS modules. SAFETY-CERTIFIED PRODUCT IDENTIFICATION Safety Certification of all GT3000 models meeting SIL 2 safety standards is clearly identified on the product label. Non-Interfering Outputs Safety Certification of the GT3000 includes the following non-interfering outputs: - LEDs and magnetic switches - HART communication The HART communication protocol is non-interfering and is to be used for diagnostics within the SIL 2 safety loop in the Safety operation mode. Diagnostics are defined as read only information. Local HART communication with the GT3000 using a handheld HART field communicator, or AMS program connected to the 4-20 mA output, is acceptable. Proper analog signal loop resistance must be installed as documented in the instruction manual to enable local HART communication. The UD20 is a loop-powered device that is approved for use in-line with a Safety-Certified GT3000. The GT3000 comes with one of two pre-programmed fault output levels: 2.45 mA or 3.5 mA. The UD20 must only be used in conjunction with 3.5 mA fault level GT3000 versions. 3.1 2 95-8685 INSTALLATION START-UP AND COMMISSIONING NOTE For complete information regarding performance, installation, operation, maintenance and specifications of the GT3000 Series, refer to instruction manual 95‑8616. Commissioning Personnel The Safety Certified GT3000 Gas Detector can be commissioned by any qualified person with knowledge of gas detection instruments and the configuration device being used. No special or additional detector installation requirements exist above and beyond the standard installation practices documented in the GT3000 instruction manual. Refer to the Installation and Calibration sections provided in the GT3000 instruction manual. Configuration The operating temperature range for the Safety Certified GT3000 depends on the specific sensor being used. Refer to the GT3000 instruction manual for details. Other environmental operating specifications are applicable as published in the general specifications section in the GT3000 instruction manual. A HART handheld device can be used to monitor internal status or to modify the factory settings of the GT3000. Refer to the GT3000 HART Communication section of the instruction manual for guidance on using HART communication. The GT3000 operating power distribution system should be designed and installed so the GT3000 terminal voltage does not drop below 12 Vdc when measured at any specific location. The external system providing power to the GT3000 must have over-voltage protection that ensures supply voltage does not exceed 30 Vdc. NOTE Prior to device configuration all alarm outputs must be bypassed. The device is not safety certified during configuration change activities. NOTE All configuration changes to the GT3000 must be verified by the user via a proof test, power cycle and re-check of settings, or other appropriate method. note All safety functions of the GT3000 are active within 150 seconds of power-up without any user action required. Configuration Protection Upon completion of installation and commissioning, it is required that the user password-protect the GT3000 safety related parameters that are accessible via HART in order to prevent accidental or deliberate change of configuration data during normal operation. To password protect the GT3000, the user must set the write-protect function to “on” and enter an 8 character password. Common Misuse Scenarios Refer to the Installation and Maintenance sections of the instruction manual for information on avoidance and resolution of common misuse scenarios. Applications to avoid include the following: - Locations where impact mechanical stress is likely. or other excessive - Locations where regular contamination from debris, trash, snow, mud, etc. is likely to contact the sensor. The user will be required to disable write protect prior to any future configuration changes, and must re‑enable write protect upon completion of these changes to ensure that HART communication remains non‑interfering. - Horizontal mounting of the GT3000 (see DEVICE MOUNTING ORIENTATION section of the GT3000 Instruction Manual). - Locations where sensor cross-sensitivity to other gases will be a problem (see Appendix A of the GT3000 Instruction Manual for details). NOTE If the user suspects that damage or misuse has occurred to the GT3000, a full proof test shall be performed. 3.1 3 95-8685 Table 1—Frequency for Performing Proof Tests GT3000 Proof Test Name Commissioning Frequency Visual Field Inspection Proof Test Yes As needed, depending on level and type of contaminants present Response Proof Test Yes 1 year OPERATION, MAINTENANCE, INSPECTION AND PROOF TESTING Response Proof Test Tools Required: Compressed Calibration Gas Kit provided by Det-Tronics All normal installation and field calibration recommendations as documented in the GT3000 instruction manual are applicable to the Safety Certified GT3000 Gas Detector. This proof test, commonly referred to as a “gas bump test”, requires application of high accuracy compressed calibration gas to the detector while in NORMAL operational mode and inspecting the signal output level to ensure that the signal output is accurately indicative of the applied test gas concentration. Safety-Certified GT3000 gas detectors require Proof testing to be performed in all cases. Personnel performing Proof Test procedures shall be competent to perform the task. All proof test results must be recorded and analyzed. Any corrective actions taken must be documented in the event that an error is found in the safety functionality. The Proof tests must be performed at a frequency as shown in Table 1. Warning Any external alarm equipment, systems or signaling devices that could be automatically initiated by performing this test must be disabled or bypassed before performing this test! warning Failure to perform the specified testing and inspection may lower or void the SIL rating for the product or system. Proof Test Sequence 1. Inhibit alarm and fault response at the control device. 2. Apply calibration test gas to the sensor. Visual Field Inspection Proof test Tools Required: 3. Verify correct change of state at the control device for the GT3000 4-20 mA output. Criteria for the 4-20 mA inspection pass is a response signal within ±10% for H2S and ±0.5% V/V for O2 of applied gas concentration (generally, a 50% full scale test concentration is applied). None Visual inspection of all Safety-Certified GT3000 gas detectors shall be conducted as needed to confirm that no external blockage of gas/vapor path into the sensing chamber exists, eg. debris, trash, snow, mud, external equipment, etc. Corrective action shall include removal of such impediments should they exist. All gas detectors must be inspected to ensure that they are capable of providing expected performance and protection. 4. Remove the test gas and ensure that the unit returns to normal operation. 5. Re-activate alarm and fault response at the control device. If response test is not within acceptable limits or fails for any reason, a Full Calibration procedure must be performed and the Proof Test re-performed. Completion of Visual Field Inspection Proof test must be recorded and documented in the SIS logbook. 3.1 4 95-8685 FAULT/FAILURE ACTION PLAN Calibration In the event that a Calibration does not result in an acceptable Response Proof test, then the standard Maintenance and Device Repair and Return procedures as listed in the GT3000 instruction manual must be followed. Any failure to successfully complete the Response Proof Test must be recorded and documented in the SIS logbook. Tools Required: Compressed Calibration Gas Kit provided by Det-Tronics Magnet or HART Communicator Calibration shall be conducted when required as documented in the Calibration section of the GT3000 instruction manual. It is permissible to conduct the calibration using either the onboard magnetic calibration switch or using an approved HART handheld field communicator. In all cases the GT3000 and attached transmitter should be allowed to warm up for one hour minimum before conducting calibration. PRODUCT REPAIR Field repair of the GT3000 is limited to replacement of the filter and/or sensor module. All other device repairs must be conducted at the factory. No firmware changes are permitted or authorized. All failures detected by the device diagnostics or by the Proof Tests that cannot be resolved through the procedures described in the FAULT/FAILURE ACTION PLAN section must be reported to the manufacturer. Completion of the Response Proof Test must be recorded and documented in the SIS logbook. WARNING Any external alarm equipment, systems or signaling devices that were disabled must be re-activated at the conclusion of proof testing activities. OPERATING, ENVIRONMENTAL, AND PERFORMANCE SPECIFICATIONS The Safety-Certified GT3000 product versions fully comply with, and must be operated in accordance with the functional, environmental, and performance specifications provided in the GT3000 instruction manual. A 24 hour mean time to repair should be assumed for safety availability calculations. All GT3000 diagnostics have a maximum one hour test interval. SPARE PARTS Refer to “Ordering Information” in the GT3000 instruction manual. Safety Certification is based on a sufficient number of spares to achieve a 24 hour mean time to repair. 3.1 5 95-8685 CERTIFICATION AND FAILURE RATE DATA Additional CERTIFICATIONS All Safety-Certified GT3000 Gas Detectors are certified compliant to: FM, CSA, ATEX, IECEx, CE, and others. Refer to the GT3000 Instruction Manual for details. For complete information regarding performance, installation, operation, maintenance and specifications of the GT3000, refer to instruction manual 95‑8616. IEC61508: 2010 Type B Element Systematic Capability: SIL 2 certified TERMS AND DEFINITIONS HFT: 0 Low Demand Mode AMS Asset Management System PFDavg should be calculated for any safety instrumented function using the GT3000. (Refer to FMEDA report for necessary information, including DU rate.) FMEDA Failure Mode Effects and Diagnostics Analysis HART Highway Addressable Remote Transducer HFT Hardware Fault Tolerance LFL Lower Flammable Limit V/V Percent by volume PFD Probability of Failure on Demand (Probability of Dangerous Failure) PFDavg Average Probability of Failure on Demand SFF Safe Failure Fraction SIF Safety Instrumented Function SIL Safety Integrity Level SIS Safety Instrumented System GT3000 Electrochemical Gas Sensor (consists of one GTX Transmitter and one GTS Sensor Module) Safety Accuracy: ±10% of applied gas concentration. Safety Response Time: Depends on sensor module being used. Refer to GT3000 instruction manual for details. Product Life: 3-5 years, based on manufacturer data. All failure rate data for SIL verification is in the FMEDA report, which is available upon request. IEC 61508 Failure Rates in FIT1 Device lsd lsu2 ldd ldu SFF3 GT3000 Analog Output with O2 Sensors 0 243 3123 141 96.0% GT3000 Analog Output with H2S Sensors 0 199 3136 275 92.4% GT3000 Analog Output with H2S+ Sensors 0 194 3151 271 92.5% FlexVu™ Universal Display UD20 adder4 0 54 36 19 – 1 FIT = 1 Failure / 109 Hours 2 It is important to realize that the No Effect failures are no longer included in the Safe Undetected failure category according to IEC 61508, ed2, 2010. 3 Safe Failure Fraction needs to be calculated on (sub)system level. 4 Add these FITs to any GT3000 version above when UD20 is used. ­Corporate Office 6901 West 110th Street | Minneapolis, MN 55438 USA Operator: 952.941.5665 or 800.468.3244 Customer Service: 952.946.6491 or 800.765.3473 | Email: Specifications subject to change without notice. All trademarks are the property of their respective owners. © 2015 Detector Electronics Corporation. All rights reserved. 95-8685