Emerson | 1052 | Instruction manual | Emerson 1052 Instruction manual

Instruction Manual Supplement
1052 Actuator
October 2013
Safety manual for Fisherr 1052 Actuators
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.
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 Process Management sales office.
This manual provides necessary requirements for meeting the IEC 61508 or IEC 61511 functional safety standards.
Figure 1. Fisher 1052 Actuator
Size 33
1052 Actuator
Instruction Manual Supplement
October 2013
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
safety­related systems.
Fail­Safe State: State where valve actuator is de­energized and spring is extended.
Fail Safe: Failure that causes the valve to go to the defined fail­safe 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
fail­safe 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 safety­related system is no
greater than twice the proof test frequency.
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
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 safety­related systems where Safety Integrity Level 4 has the highest
level of safety integrity and Safety Integrity Level 1 has the lowest.
Instruction Manual Supplement
1052 Actuator
October 2013
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:
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
D Safety Integrity Level Selection — Systematic Methods Including Layer of Protection Analysis, ISBN 1­55617­777­1,
D Control System Safety Evaluation and Reliability, 2nd Edition, ISBN 1­55617­638­8, ISA
D Safety Instrumented Systems Verification, Practical Probabilistic Calculations, ISBN 1­55617­909­9, ISA
Reference Standards
Functional Safety
D IEC 61508: 2010 Functional safety of electrical/electronic/ programmable electronic safety­related systems
D ANSI/ISA 84.00.01­2004 (IEC 61511 Mod.) Functional Safety — Safety Instrumented Systems for the Process Industry
Product Description
The Fisher 1052 is a spring and diaphragm rotary actuator.
The 1052 actuator can be installed on rotary­shaft valve bodies for throttling or on­off applications. The actuator
linkage features a clamped shaft lever and a single pivot point to reduce lost motion between the actuator and the
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 o­ring seals, the double­sided diaphragm in the 1052
actuator provides a longer service life.
Powder paint coating is standard and offers an excellent corrosion­resistant finish on all external steel and cast iron
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.
1052 Actuator
Instruction Manual Supplement
October 2013
Designing a SIF Using a Fisher 1052 Actuator
Safety Function
When the 1052 actuator is de­energized, the actuator and valve shall move to its fail­safe 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 on­site 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 Process Management. 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
Instruction Manual Supplement
1052 Actuator
October 2013
beyond the useful lifetime may yield results that are too optimistic, i.e. the calculated Safety Integrity Level will not be
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
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 start­up.
The user shall verify that the 1052 actuator is suitable for use in safety applications.
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Instruction Manual Supplement
October 2013
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.
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
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
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.
Instruction Manual Supplement
1052 Actuator
October 2013
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 Process Management. 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
Bypass the safety function and take appropriate action to avoid a false trip.
Interrupt or change the signal/supply to the 1052 actuator to force the actuator and valve to perform a full stroke to the Fail­Safe state and
confirm that the Safe State was achieved and within the correct time.
Restore the supply/signal to the 1052 actuator and confirm that the normal operating state was achieved.
Inspect the 1052 actuator and the other final control element components for any leaks, visible damage or contamination.
Record the test results and any failures in your company's SIF inspection database.
Remove 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 Process
Management. Please contact Emerson Process Management customer service or your local Emerson Process
Management service representative.
Status of the Document
Version History:
(Version, Status, Date)
Instruction Manual Supplement
1052 Actuator
October 2013
Appendix A
Sample Startup Checklist
This appendix provides a sample Start­up Checklist for a 1052 actuator. A Start­up 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
Target Safety Integrity Level and PFDAVG determined
Correct valve mode chosen (Fail­closed, Fail­open)
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
Design formally reviewed and suitability formally assessed
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
Tubing blockage / partial blockage tested
Safety loop function tested
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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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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
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Emerson Process Management
Marshalltown, Iowa 50158 USA
Sorocaba, 18087 Brazil
Chatham, Kent ME4 4QZ UK
Dubai, United Arab Emirates
Singapore 128461 Singapore
8E 2013. Fisher Controls International LLC. All rights reserved
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