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NELES VALVGUARD SYSTEM, INTRINSICALLY SAFE CONSTRUCTION VG800X

The Metso Automation Neles ValvGuardTM system is intended to be used on applications where automated Emergency Shut Down (ESD) or Emergency Venting (ESV) valve testing is needed. Neles ValvGuard takes care of this testing automatically, using partial stroke testing where the ESD-valve is closed only partially and not affecting the flow in the pipeline. A clear signal will be given to the control room of the status of valve (OK, testing, alarm). Based on the information data, plant production can be optimized and in case of need predictive maintanence plans can be made. Unnecessary and expensive manual testing can be avoided. This in long term can be a major cost saving at plant, without jeopardizing the plant safety rules.

The VG800X uses the standard 24 VDC input, which is normally used for solenoid valves, so no additional wiring is needed. Therefore installation costs are kept at minimal level. Neles ValvGuard system can be fitted into existing valve-actuator combination with custom made linkage parts. Typical applications are: Emergency Shut-Down (ESD), where such valves form part of the emergency plant shut-down isolation strategy to prevent plant over-pressure. Blow-down Valves (BDV), where such valves form part of the emergency plant shut-down de-pressurization strategy to prevent plant over-pressure. Other key on/off valve applications, where valve availability is essential or critical. The VG800X has no internal Iinks between modules. As a result, it is highly resistant to wear and to the effects of vibration. All moduels are easily replaceable in the field. The rugged cover protects the unit from environmental hazards and external abuse. The basic enclosure is intrinsically safe according to ATEX, EEx ia IIC T5/T6 certification (for other certifications, see options).

test, which is used for testing the pneumatical parts of VG800X, like the spool valve and instrumentation. Already existing intrumentation, for example exhaust valves, can be used to enhance the performance of the ESD-valve. Applications include the use with all on/off valves in process plants where the "availability" of such valves is perceived as critical for plant safety or operational control.

Economical and easy to use

Easy adjustment and parameter settings with local keypad and display, or by using HART connection and FieldCare software.

Diagnostics

Built-in diagnostic capabilities accessed via the HART communication connection allow predictive maintenance based trend analysis. Graphical user interface, FieldCare software can be linked into General Plant Management Systems.

9 VG 20EN · Issue 12/2003

TÜV certificate

Neles ValvGuardTM has been tested and approved for use in ESD/ESV applications, up to SIL 3 (Safety Integrity Level 3).

Automatic test of emergency valve performance

Test intervals and stroke size can be preprogrammed as parameters into VG800X field device. Then partial valve stroke tests are done at prefixed time intervals that match the Safety Integrity Level requirements of the particular application. Testing includes also a pneumatics

CE-mark

The VG800X carries the CE-mark concerning countries which belong to the European Economic Area.

M E T S O AU TO M AT I O N

Excellent vibration resistance

Contactless position feedback sensor and spool valve drive do not depend on mechanical links which can be affected by vibration. The position sensor is immune to wear and unaffected by dirt. Rugged construction, small moving masses and modular design with few parts. Position signal free of electrical disturbance

board temperature, Valve leakage (optional). Diagnostics; Breakaway pressure and load factor trend, Valve leakage trend (optional). Testing; Partial Valve and pneumatics tests.

Installation

Suitable for rotary and linear spring-return or double-acting pneumatic actuators in different sizes.

Enclosure Leakage Sensor

Possible increased leakage trend can be monitored with optional leakage sensor. Intrinsically safe construction, aluminium alloy. Metal case provides Faraday cage effect to protect electronics from EMC interference. Protects against mechanical damage. Protection class according to IEC IP65, Nema 4 and 4X.

Local keypad and LCD display

Time-saving self-calibration. No need for hand-held terminal during installation. Locking feature against parameter change.

Options

FieldCare software for communication. Pressure gauge kit. Air set. Conduit entries; PG13.5, 1/2" NPT. Leakage sensor. Built-in proximity switches. Position transmitter, output 4-20 mA. Explosion proof version also available. See Bulletin 9VG/ B20.

FieldCare

An embedded HART modem on the circuit board allows remote parameter settings and access to predictive maintenance system. Configuration; Parameter settings. On-Line Monitoring; valve position, cylinder pressure and

PRINCIPLE OF OPERATION

Neles ValvGuard is actually an operating system rather than a discreet component, smart technology enables programmable functions and communication between the control room and the remote device fitted to the ESD valve in the field. The added value which Neles ValvGuard system is expected to offer to customers is two fold: it lowers operations costs and increases safety. The VG800X field device contains a micro controller. VG800X is powered by 24 VDC supply from the plant control room. Placed at the electric cross connection room (safety area), the Remote Communication Interface (RCI) is mounted -2-

in the 24 VDC (other voltages optional) supply line. The purpose of the RCI is to provide continuous real time status information between the VG800X and the control room. Three signal conditions are provided, OK, Testing and Alarm. The RCI also permits communication between a control room PC and the VG800X, using HART communication protocol. A FieldCare software is used to interrogate, configure and collect data when connected to VG800X. Principle of the Neles ValvGuard concept is illustrated in figure above.

N E L E S VA LVG UA R D S YS T E M , VG 8 0 0 _

EXPLODED VIEW

2

CONSTRUCTION MODULES

Item 1 CONSTRUCTION Housing Cover Prestage Spool valve Circuit board Position sensor Differential pressure sensor Shaft Protective cover Ear Coupling's jacket Pointer Gasket Circuit board, PSB Material Aluminium Aluminium Stainless steel/aluminium Stainless steel/aluminium ­ ­ ­ Stainless steel Aluminium Stainless steel Plastic Plastic Rubber ­

65 46

2 *3 *4 *5 *6 *7 40 46 51

1

5

3 401 4 98 6 7

400

54 *65 98

40

*400

54 51

* Note: All these modules are replaceable. Part 4 and 98 are only recommended spare parts.

TECHNICAL SPECIFICATIONS General

Suitable for rotary and linear valves. Actuator connection in accordance with VDI/VDE 3845 standard. Action: Single-acting. Turning angle: min. 45° - max. 95° Two (SPDT) Relay outputs of RCI-unit: 24 VDC, 0.5 A RCI-module is located at electric cross connection room (safety area).

Local keypad functions

Mode selection: Auto/Off Testing: Partial valve test/pneumatic test Calibration: Automatic / Manual Power-up selection: Off/On/CAL Normal position selection: Close/open Rotation: Rot: clockwise / counterclockwise Protect (HART): Off/On Actuator type: Rotary/linear

Environmental influence

Operational temperature: -40 ...+ 85 °C / -40...+185°F . Shock requirements according to IEC TC65B draft.

Enclosure

Material: Protection class: Pneumatic ports: Electrical connection: Conduit entry: Weight: Anodized aluminium alloy. IP65, Nema 4 and 4 x. 1/4 NPT. Screw terminal internals for 2.5 mm2. PG 13,5 1/2" NPT (with adapter). 2.6 kg / 5.7 lbs.

Approvals

Intrinsically safe (X): ATEX II 1 G EEx ia IIC T5/T6 (EN 50014, EN 50020, EN 50284) or ATEX II 2 G EEx ia IIC T5/T6 (with options I01 and T1) and ATEX II 3 G EEx nL IIC T5/T6 (EN 50014, EN 50021) and Ex nL IIC T5/T6 (IEC 60079-15: 2001) and Ex N IIC T5/T6 (BS 6941: 1988) Non Incendive (NU): FM Class I. Division 2, Groups A,B,C and D certification. TÜV: 968/EL 156.00/01

Pneumatics

Supply pressure: Air quality: Capacity: 3.5-7 bar / 50-100 psi (filter regulator mandatory). as defined by ISA S7.3 standard. max. 30 Nm 3 /h / 18 scfm at 4 bar / 60 psi supply.

User interfaces Electronics

Supply voltage: Polarity protection: Voltage range: Maximum current: 24 VDC -30 VDC. 16.5-28 VDC (I-load 20 mA). 100 mA (RCI-VG800) 200 mA (RCI-Ex isolator-VG800). Intrinsically safe specification Terminals 1 & 3: Uo = 28 VDC Io = 120 mA Po = 1 W Co = 5.5 nF Lo ~ 0 H RCI-Input: 21 - 30 VDC (30 - 60 VDC optional), I = 100 mA Local: HART: 3 keys + LCD display. PC with a HART modems together with FieldCare software.

Electromagnetic protection

Protection standards: EN50081-1 and EN50082-2 IEC 801-2 ESD, level 4 IEC 801-3 electromagnetic field, level 3 IEC 801-4 Fast Transients, level 4.

CE marking

Electromagnetic compatibility: -389/336/EEC.

M E T S O AU TO M AT I O N

DIMENSIONS, mm / inch

VG8568_

0.90 21 0.83 23 1/4NPT

PG13.5

C2

4.60

117

1.30

33

S

23.5

0.93

1.30

33

C1

M6x12

4 0.16 23 0.90 137 5.39 47.5 1.87

(0.12)

(3)

0.98

25

F05-Ø50(VDI/VDE3845) (35.4) (1.39)

RCI

(35.4)

(1.39)

39.5

1.55

5.39

137

M6/10

104

16

- L = 1/2 NPT -I = M20x1.5 - NJ = R1/2

VG8568_I01, VG8568_T1, VG8568_T3 and VG8568_I01NU

PG13.5 21 0.83 VG85-S1 (rotary) PG13.5 6.77 172 ø6 ø0.24

C2

(1.02)

(26)

1/4 NPT 23 0.90

110

(35.4) (1.39) M6 / 10 (VDI/VDE 3845) F05-ø50 4 0.16 M5 / 18

70 2.76

46 1.81

38 1.49

23.5 0.93

13.9 0.55

C1

2 0.08 44 1.73 137 5.39

23 0.90

47.5 1.87 39.5 1.55 VG85-A1 (linear) 29 1.14 5 0.20

C2

5.39

137

ø0.59

ø15

- L = 1/2 NPT -I = M20x1.5 - NJ = R1/2

(1.02)

(26)

-4-

33 1.30

S C1

33 1.30 (35.4) (1.39)

55 2.16

26.8 1.05

S

N E L E S VA LVG UA R D S YS T E M , VG 8 0 0 _

HOW TO ORDER

1. 2. 3. 4. 5. 6. 7. 8. 9.

VG 1. sign VG

8

5

68 PRODUCT GROUP

X

S1

A

SL 7. sign N A

I01 PRESSURE GAUGES ON THE SSV No pressure gauges. Pressure gauges, scale bar/psi/kPa, basic material brass, nickel platedhousing stainless steel. Glycerine filled. Temperature range for gauges -40°C... +70°C / -40°F +158°F ... .

Neles ValvGuard for emergency shutdown valves, including only the field device. The remote communication interface module (RCI) has to be specified separately.

2. sign 8

SERIES CODE 8. sign SL INPUT SIGNAL RANGE 0/24 VDC binary on/off-signal. LEAKAGE SENSOR Acoustic sound sensor. Voltage: 3.3 VDC, I< 10 mA.

3. sign 5

9. sign

LIMIT SWITCH TYPE Inductive proximity switches (I), 2 pcs. P+F; NJ2-12GK-N. DC > 3 mA; < 1 mA. 2-wire type. Intrinsically safe according to ATEX II 2 G EEx ia IIC T5/T6 (EN 50014, EN 50020) Electrical classification shall always be X (5. sign). Temperature range -25 °C...+65 °C / -13 °F ...+149 °F . P+F; NJ2-12GK-N. DC>3mA; <1mA Non incendive according to FM Class I, Division 2, Groups A, B, C, D Electrical classification shall always be NU. Temperature range -25 °C...+65 °C / -13 °F ...+149 °F .

4. sign 68

SPOOL VALVE Single action.

CONNECTIONS (S, C2) 1/4 NPT

I01

5. sign

ELECTRICAL CLASSIFICATION Intrinsically safe constructions Intrinsically safe construction. ATEX II 1 G EEx ia IIC T5/T6 (EN 50014, EN 50020, EN 50284) or ATEX II 2 G EEx ia IIC T5/T6 (with options I01 and T1) and ATEX II 3 G EEx nL IIC T5/T6 (EN 50014, EN 50021) and Ex nL IIC T5/T6 (IEC 60079-15: 2001) and Ex N IIC T5/T6 (BS 6941: 1988) Temperature range T5; -40 °C...+65 °C / -40 °F ...+149 °F T6; +50 , °C / +122 °F . Supply voltage 16.5 - 28 VDC. PG 13.5 conduit entry. Non-incendive construction. FM Class I. Division 2, Groups A, B, C and D certification. Temperature range T5; -40 °C...+80 °C / -40 °F ...+176 °F , T6; -40 °C...+75 °C / -40 °F ...+167 °F . Supply voltage 16.5 - 28 VDC. 1/2 NPT conduit entry (with adapter). I01NU

X

-

T1

Position transmitter Camille Bauer KINAX 3W2. Intrinsically safe according to II 2 G EEx ia IIC T6. Available only with option X. Analog position feedback signal, output 4-20 mA. 2-wire connection (passive). Not compatible with limit switch options I. Temperature range -40 °C ...+60 °C / -40 °F ... +140 °F . Camille Bauer, KINAX 57-3W2, Non incendive; FM Class I, Division 2, Groups A, B, C and D. Available only with option NU. Analog position feedback signal, output 4-20 mA. 2-wire connection (passive). Not compatible with limit switch options I. Temperature range -20 °C ... +65 °C / -4 °F ... +149 °F .

NU

T3

6. sign S1

ACTUATOR CONNECTION Rotary motion. Attachment face according to standard VDI/VDE 3845, equipped with an H-clip. When separate deliveries, VDI/VDE 3845 ear is supplied. Linear motion. Also applicable to linear actuators according to IEC 60534-6-1 with own linkage set. Special construction, to be specified.

A1 YY

-5-

M E T S O AU TO M AT I O N

Subject to change without prior notice.

Metso Automation, Field Systems Europe, Levytie 6, P.O. Box 310, 00811 Helsinki, Finland. Tel. +358 20 483 150. Fax +358 20 483 151 North America, 44 Bowditch Drive, P.O. Box 8044, Shrewsbury, MA 01545, USA. Tel. +1 508 852 0200. Fax +1 508 852 8172 Latin America, Av. Central, 181-Chácaras Reunidas,12238-430 São José dos Campos, SP Brazil. Tel. +55 123 935 3500. Fax +55 123 935 3535 Asia Pacific, 501 Orchard Road, #05-09 Wheelock Place, 238880 Singapore. Tel. +65 673 552 00. Fax +65 673 545 66 Middle East, Roundabout 8, Unit AB-07, P.O. Box 17175, Jebel Ali Freezone, Dubai, United Arab Emirates. Tel. +971 4 883 6974. Fax +971 4 883 6836 www.metsoautomation.com

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