SAFETY MANUAL Electrochemical Toxic Gas Detector GT3000

SAFETY MANUAL Electrochemical Toxic Gas Detector GT3000
SAFETY MANUAL
Electrochemical Toxic Gas Detector
GT3000 Series
Includes Transmitter (GTX)
with H2S or O2 Sensor Module (GTS)
Sensor
Module
(GTS)
Transmitter
(GTX)
SAFETY CERTIFIED GT3000 Series
Electrochemical Toxic 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 Toxic 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.
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 Toxic 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.
1.1© Detector Electronics Corporation 2012Rev: 3/1295-8685
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 Toxic 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
- Display via UD20*
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 has been evaluated as a non-interfering
loop-powered device and 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 3.6 mA. The UD20 must only be used in
conjunction with 3.6 mA fault level GT3000 versions.
1.1
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 Toxic 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.
1.1
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 Toxic 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.
1.1
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.
1.1
5
95-8685
CERTIFICATION AND FAILURE RATE DATA
Additional CERTIFICATIONS
All Safety-Certified GT3000 Toxic 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 Toxic 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
Failure Category
lsd
lsu2
ldd
ldu
SFF3
GT3000 Analog Output with H2S Sensors
0
199
3136
275
92.4%
GT3000 Analog Output with O2 Sensor
0
243
3123
141
96.0%
1FIT = 1 Failure / 109 Hours
2It 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.
3Safe Failure Fraction needs to be calculated on (sub)system level.
ED
ER
BY UL
AN
Detector Electronics Corporation
D
BS
I
NO
.
M
TER
ED FIR
A 23
TE
RM
ISO 9001
S
REGI
©Copyright Detector Electronics Corporation 2012. All rights reserved.
T
IS
REGIS
Det-Tronics, the DET-TRONICS logo, and FlexVu are registered trademarks
or trademarks of Detector Electronics Corporation in the United States,
other countries, or both. Other company, product, or service names may be
trademarks or service marks of others.
RE
G
Specifications subject to change without notice.
RED FI
05 • NO. 25
82
6
6901 West 110th Street • Minneapolis, Minnesota 55438 USA
Operator: (952) 941-5665 or (800) 765-FIRE
Customer Service: (952) 946-6491 • Fax (952) 829-8750
http://www.det-tronics.com • E-mail: det-tronics@det-tronics.com
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertising