IQ SIL Option sira

CERTIFICATION

IQ actuators for use in applications up to SIL 3

Keeping the World Flowing

RELIABILITY
IN FLOW CONTROL
CRITICAL
APPLICATIONS

RELIABLE OPERATION QUALITY-DRIVEN

WHEN IT MATTERS GLOBAL MANUFACTURING

Assured reliability for critical applications and environments. Rotork products are designed with 60 years of industry
and application knowledge.
Whether used 24/7 or very infrequently, Rotork products
will operate reliably and efficiently when called upon. Research and development across all our facilities
ensures cutting edge products are available for
every application.

CUSTOMER-FOCUSED SERVICE LOW COST

WORLDWIDE SUPPORT OF OWNERSHIP

Rotork focus on solving customer challenges and Long-term reliability prolongs service life, reducing long
developing new solutions, from initial enquiry through to term cost of ownership and providing greater efficiency
product installation, long-term after-sales care and client to process and plant.
support programmes.

2 IQ SIL Option
 IQ SIL Option
Section Page

Rotork 2
IQ Actuators 4
rd
Available 3 Generation IQ SIL Actuators 6
IQ SIL Reliability Data for SIL Applications 7
Advanced IQ Features for SIL Applications 8
Typical Remote Control Circuit Diagram 9
IQ Remote Control Circuitry for SIL Applications 10
SIRA Certificate 11

COMPREHENSIVE PRODUCT RANGE MARKET LEADER

SERVING MULTIPLE INDUSTRIES TECHNICAL INNOVATOR

Rotork products and services are used in the Power, The recognised market leader for sixty years.
Oil & Gas, Water & Waste Water, HVAC, Marine, Mining,
Food & Beverage, Pharmaceutical and Chemical industries Our customers have relied upon Rotork for innovative
around the world to improve efficiency, assure safety and solutions to safely manage the flow of liquids, gases
protect the environment. and powders.

GLOBAL PRESENCE CORPORATE SOCIAL

LOCAL SERVICE RESPONSIBILITY

Global company with local support. Rotork believes that being a responsible business leads
to being the best business.
Manufacturing sites, offices and Centres of Excellence
throughout the world provide unrivalled customer services We are socially, ethically, environmentally responsible
and fast delivery. and committed to embedding CSR across all our
processes and ways of working.

Keeping the World Flowing 3

The most robust actuator design
in the industry providing
exceptional reliability

Suitable For Use in Safety

Systems up to SIL 2/3

As Standard, IQ has the

Ability to Stayput in a SIL 2
Safety System

IQ SIL Option Allows an

ESD Safety Function

Partial Stroke Capabilities

Full Datalogger Available

4 IQ SIL Option
Supported by Rotork

Externally Certified

Supported by Full Reliability Data

Compliments Rotork’s Range

of Electro-Hydraulic
Spring-Return Actuators

For Part-Turn Applications the

IQT has the Ability to Stayput in
Safety Systems up to SIL 2

Keeping the World Flowing 5

Available 3rd Generation IQ SIL Actuators sira
CERTIFICATION

Rotork IQ actuators including the SIL Safety Safety Functions

Function Control Module option are SIRA The two safety functions applicable to valve actuators are:
certified for use in SIL 2 safety applications
Safety Function 1 – Stayput (High Demand)
using a 1 out of 1 actuated valve configuration
The actuator shall not move without a valid Motor Enable
(1oo1). Safety functions are “Stayput” and “ESD”.
command signal. If an internal failure is detected the actuator
Where SIL 3 is required, IQ SIL may be used will give an alarm signal.
in a 1oo2 actuated valve configuration
In order to meet the requirements of SIL 2 for safety function 1
(redundant mode).
the actuator must be controlled for opening and closing using
2 input signals; motor enable and a control command from
For the types shown below there is no restriction on actuator
a remote input or a network command. If the motor enable
size or speed. Refer to publication PUB002-038 for actuator
signal is not present, the actuator will not move. If the motor
sizes, speeds and torque performance details.
enable signal is removed while in operation, the actuator will
Due to the strict design and implementation requirements stop. Safety function 1 can be configured for operation in local
necessary, IQ SIL option is limited to the actuator type, power control mode in addition to remote operation.
supply and duty rating displayed in the table below. For more
Safety Function 2 – ESD (Low Demand)
information on control and monitoring options available with
the IQ SIL option, refer to page 8. If an ESD signal is active, the actuator will perform the
commissioned ESD action (open, close or stayput). If an internal
Operation failure is detected the actuator will give an alarm signal.

The SIL option replaces the standard IQ control board to For safety function 2, a single, maintained ESD signal derived
provide diagnostic coverage and redundant control in order from a normally closed contact (break to ESD) is required. ESD
to carry out the specified safety function. In addition, electro- operation will override any existing remote open or close signal
mechanical and mechanical component reliability has been while applied. Safety function 2 can be configured for operation
assessed and quantified, meeting reliability requirements of in local and/or stop mode in addition to remote mode.
SIL 1/2/3 applications.
Combined Safety Functions 1 & 2 – Motor Enable with ESD
A safety function status relay provides indication of the To stayput as per safety function 1 or perform the
actuator's safety function ability to complete. Status is also commissioned ESD action as per safety function 2. Safety
duplicated locally on the actuator display. function 1 or safety function 2 can be set as the priority
In order to meet the requirements of SIL as certified by SIRA, action. Safety function operation can be configured for local
IQ SIL actuators must be installed, commissioned, operated and/or stop in addition to remote mode.
and maintained/proof tested in accordance with the safety
manual publication PUB002-057.

Basic Circuit
Type Duty Power supply Duty rating Starts/Hr
Diagram
Function 1:
Stayput
Safety

Multi-turn isolating and S2/S3,

IQ 3-phase supply 60 700B0000
Quarter-turn isolating Class A & B
Function 2:
Safety

Multi-turn isolating and S2/S3,

ESD

IQ 3-phase supply 60 700B0000

Quarter-turn isolating Class A & B

6 IQ SIL Option
IQ SIL Reliability Data for SIL Applications sira
CERTIFICATION

The reliability data provided is applicable to the The reliability data in the tables below assume powered
complete actuator up to and including the actuator operation (PO) has been carried out at least once every six
output drive assembly. It does not include the valve, months. Refer to PUB002-057 or SIRA certificate FSP 150001
valve drive components or second stage gearboxes. The for full reliability data information.
integrity/reliability of the electrical power supply and user
derived control signals are not included in the actuator
reliability assessment.

Safety Function 1: Stayput Symbol IQ10 - 18 IQ19 - 25 IQ35 IQ40 IQ70 - 95

Subsystem Type Type B Type B Type B Type B Type B

Hardware Fault Tolerance HFT 0 0 0 0 0

Safe Diagnosed Failures sd 0 0 0 0 0

Safe Undiagnosed Failures su 1.15E-05 1.15E-05 1.15E-05 9.60E-06 9.60E-06

Dangerous Diagnosed Failures dd 0 0 0 0 0

Dangerous Undiagnosed Failures du 4.00E-07 5.00E-07 6.00E-07 4.40E-07 4.70E-07

Probability of failure per hour PFH 5.00E-07 5.00E-07 5.00E-07 4.60E-07 4.60E-07

Safe Failure Fraction SFF 96% 96% 96% 95% 95%

SIL Capability SIL 2 SIL 2 SIL 2 SIL 2 SIL 2

Safety Function 2: ESD (to move) Symbol IQ10 - 18 IQ19 - 25 IQ35 IQ40 IQ70 - 95

Proof Test Interval (Hours) T1 8760 8760 8760 8760 8760

Mean Time to Repair MTTR 24 24 24 24 24

Subsystem Type Type B Type B Type B Type B Type B

Hardware Fault Tolerance HFT 0 0 0 0 0

Safe Diagnosed Failures sd 1.98E-05 8.24E-06 8.24E-06 8.18E-06 8.18E-06

Safe Undiagnosed Failures su 6.62E-05 6.41E-05 6.45E-05 6.35E-05 6.25E-05

Dangerous Diagnosed Failures dd 7.34E-07 7.68E-07 7.68E-07 7.84E-07 7.84E-07

Dangerous Undiagnosed Failures du 1.70E-06 1.96E-06 1.88E-06 1.77E-06 2.51E-06

Diagnostic Coverage DC 30% 28% 29% 31% 37%

Safe Failure Fraction SFF 98% 97% 97% 98% 97%

Probability of Failure on Demand PFD 4.00E-03 4.60E-03 4.40E-03 4.10E-03 5.80E-02

SIL Capability (Low demand mode) SIL 2 SIL 2 SIL 2 SIL 2 SIL 2

Certificate reference: Size 1 = IQ10, IQ12, IQ18 Size 2 = IQ19, IQ20, IQ25 Size 3 = IQ35 Size 4 = IQ40, IQ70 Size 5 = IQ90, IQ91, IQ95

Keeping the World Flowing 7

Advanced IQ Features for SIL Applications sira
CERTIFICATION

Actuator selection and sizing In order to meet the requirements of SIL 2 for safety
function 1, the actuator must be controlled for opening and
The selection of actuator type and size is dependent on the closing using 2 input signals; motor enable and a control
valve type (multi-turn or part-turn) and the required operating command from a remote input or a network command. If the
forces (torque and/or thrust). Actuator performance data motor enable signal is not present, the actuator will not move.
is provided in publication PUB002-038. An online actuator If the motor enable signal is removed while in operation, the
sizing guide is available at www.rotork.com. Contact Rotork actuator will stop.
for further help or advice.
For safety function 2, a single, maintained ESD signal derived
The following conditions will be applied: from a normally closed contact (break to ESD) is required.
• Rotork will size the actuator based on the supplied valve ESD operation will override any existing remote open or close
data. No additional safety factors will be added unless signal while applied.
expressly requested. Safety function 1 and safety function 2 can be configured to
• The valve or valve drive components must be capable override local control and stop mode.
of safely withstanding the supplied actuator stall torque
and/or developed thrust at stall torque. For design Actuator indication
purposes, stall torque must be considered to be at least
Fault status relay
2 times supplied actuator/actuator-gearbox combination
rated torque. The SIL option includes a status relay contact providing
remote indication that the system has detected an invalid or
• Under ESD operation to open or close (safety function 2), fault condition and has performed the safety function, or, the
torque protection at the set value is active for valve seating safety function cannot be applied or could be overridden. The
unless set to stop on position. If the valve is obstructed actuator LCD display also provides fault status indication.
mid travel during stroke, the actuator will apply up to stall
torque in an attempt to complete the safety function. In Indication contacts
the unlikely event of position sensor failure, stall torque The actuator has 4 configurable contacts, S1 to S4 available
may be developed at any position (obstructed / seating). for indication including open and closed position limit
indication and intermediate position indication (configurable).
Actuator power An optional 4 configurable contacts, S5 to S8 can be
The actuator electrical power supply integrity does not fall provided if additional relay indication is required.
within the scope of the actuator reliability data. Users must A full list of available functions is provided in publication
ensure the integrity of the actuator power supply meets the PUB002-040.
requirements of the target SIL for the SIS.
Monitor relay
The monitor relay will indicate one or more of the following
conditions:
• Loss of one or more of the power supply phases
• Loss of control circuitry supply
Actuator control
• Actuator selected for local control
All IQ network and analogue control options are available • Thermostat tripped
with the SIL option. Process control and reporting will be
• Local / remote control pushbutton set to Local stop
available as normal, however to invoke safety function 1 or
2 hardwired control inputs must be used and have priority.
Analogue 4-20 mA position indication
This arrangement allows the actuator to be under control of
the basic process control system (BPCS) for normal operation The Current Position Transmitter (CPT) provides a non-
by network, analogue or hardwired control while also contacting internally or externally fed 4-20 mA analogue
integrating it with the safety instrumented system (SIS) using signal proportional to valve position. Selectable for minimum
hardwired signals to prevent operation or for priority safety signal corresponding to fully Closed or fully Open position
shutdown (ESD). with automatic zero and span setting.

With a network or analogue control option fitted or with NOTE: Indication outputs S1 to S8, Monitor Relay and the CPT
basic hardwired control, for safety function 1 withdrawal analogue position signal do not fall within the scope of the
of the motor enable input signal will prevent operation. actuator reliability assessment and therefore should not form
part of the SIS.
In the case of safety function 2, on “ESD” (removal of the
hardwired signal) the actuator will carry out the ESD action as User must ensure the integrity of indication meets the
configured. Refer to example IQ3 Circuit Diagram 700B0000 requirements of the SIL target for the SIS. If necessary, limit
and control connection drawing RWS120 on the following position indication should be derived from devices external to
pages. Safety function 1 and 2 can be combined and user the actuator and driven directly from the valve obdurator.
configured as to which has priority.

8 IQ SIL Option
Typical Remote Control Circuit Diagram sira
CERTIFICATION

W
M 2
CIRCUIT DRAWN WITH POWER SUPPLY OFF
2
FOR TYPICAL REMOTE CONTROL
DETAILS, SEE DOCUMENT
3 V
4
1
3
3
PHASE
RWS120
SUPPLY
U
3 1 TRANSFORMER TAPPING OPTIONS
6
Tap Nominal 50/60Hz
5 U V W E TYPE 1
FS1 W 220/230
X 380/400
C1 C2 Y 400,415/420
U W X Y Z
Z 440/460
FUSE FS1= 250mA ANTI-SURGE
SK2 TYPE 2
0VAC 1 W 346/380
TRANSISTOR SWITCHING FOR
PS1
24VDC CONTACTORS (IQ10-35) 120VAC 4 X 480/500
RELAYS ONLY FITTED WHEN Y 240/240
0VDC
120VAC CONTACTOR IS FITTED 3 4 Z 550/575
24VDC
FOR IQ40,70,90,91 & 95 24VDC 6
_ 5 NOMINAL SUPPLY
(OUTPUT)
FUSE FS1= 250mA ANTI-SURGE

+
TYPE 3
SK14 X 660/660-690
0VDC 1
Y 690/-
24VDC 2 FUSE FS1= 150mA ANTI-SURGE

SK13

26 WAY
REFER TO SHEET 2 FOR NOTES
& OPTION PCB'S IF FITTED

SK3 SK13
6

5 SK7
4 32
TORQUE 4
3
SIL FAULT RELAY
6
SENSOR 2
1
5 40
SK8
POSITION 10 WAY
1 42
MONITOR RELAY
SENSOR 4 WAY SK15
3 43
2 44
BATTERY - SK9
4

+
1

FS2 (IF FITTED) 100mA SK4

CLOSE 9 33 MOTOR ENABLE REMOTE FUNCTION
A MOTOR ENABLE SIGNAL MUST BE APPLIED TO
MOTOR ENABLE (16-60Vdc) 34 TERMINAL 34 BEFORE AN OPEN OR CLOSED

50%
10
SIGNAL WILL OPERATE THE ACTUATOR.
MOTOR ENABLE SIGNAL MUST BE 16- 60VDC.
SK6 OPEN 8 35 MOTOR ENABLE IS NOT REQUIRED FOR LOCAL
OPERATION.
COMMON -VE 1 36
18 WAY
STOP
ESD (16-60Vdc) 12 25
CLOSE

OPEN
LOCAL
OPEN INTERLOCK 13 37
REMOTE

CLOSE INTERLOCK 14 38
COMMON -VE 5 31
SK1 SK2
SLOT A SLOT B

SIL NOTES (Superseding Sheet 2 Notes)

-ESD + Motor Enable are for DC only.
-Positive Switch Only Allowed
-Certified to IEC61508-2 (2010) as an element suitable for
use in safety related systems up to and including SIL 2 (1oo1) and SIL 3 (1oo2). Must
be installed, commissioned
and operated in accordance with the Safety Manual. Refer to SIL Safety Publication -
PUB002-057
Iss Date Chkd Revision Details IQ + SIL
1 030615 PMJ FIRST ISSUE www. .com
2 230715 PMJ SIL note extended ROTORK CONTROLS LTD ROTORK CONTROLS INC Drawn by: PMJ Circuit Diagram Number Issue Sheet

700B0000
3 081215 PMJ RWS WAS RWS100 Date : 030614 No
BATH, BA1 3JQ ROCHESTER
1
3
ENGLAND NY 14624, USA
Base WD: 700B0000
Job No : - - of 2
Tel:01225-733200 Tel:585-247-2304 MI No : - - B1 C1 B2 C2
IQ3

Keeping the World Flowing 9

IQ Remote Control Circuitry for SIL Applications sira
CERTIFICATION

IQ Remote Control Circuitry for SIL Applications

– DC Voltage Only
To meet the requirements of SIRA certificate FSP 15001 for Before putting the actuator into service, it must be installed
SIL applications the following DC remote control connections and commissioned in accordance with IQ3 SIL safety manual
must be made. The safety integrity assessment for the remote publication PUB002-057.
control circuits is the responsibility of others and does not
The Bluetooth® wireless setting tool enables configuration of
form part of the actuator assessment.
all actuator settings.

N
CUSTOMER CONNECTION FOR

LTA AL /

OW
GE
REMOTE CONTROL

GE S

TD
LTA OL

DC ITIO
LY

HU
+V PPL
VO NTR

LE
PP

VO
-VE OND

YS
AB
SU

DC L SU
DC CO

NC
E
EN
C
L

-VE MON

ES ON
-VE RNA

24V RNA

GE
R
E

TO
MM

ER
EN
OS
M
E

E
D
INT

INT
MO

EM
CO

OP
CO

# CL
4 36 31 33 35 34 5 25

SAFETY FUNCTION 1:STAYPUT

OPEN/CLOSE PUSH TO RUN CONTROL Close
Motor
Open
(LOCAL CONTROL REMAINS SELF MAINTAINED) Enable
To external supply or terminal 5
(see 'Note:' above)

#
4 36 31 33 35 34 5 25

SAFETY FUNCTION 2:ESD ESD

switch
EMERGENCY SHUT-DOWN CIRCUIT. Normally Closed
THE ESD CIRCUIT CAN BE ADDED TO THE CONTROL CIRCUIT (Break to ESD)
SHOWN ABOVE WHEN SAFETY FUNCTION 1 AND 2 ARE
To external supply or terminal 5
REQUIRED.
(see 'Note:' above)
AN ESD SIGNAL APPLIED TO THE ACTUATOR WILL OVERRIDE
ANY EXISTING OPEN OR CLOSE CONTROL SIGNAL.
MOTOR ENABLE OR ESD CAN BE CONFIGURED TO TAKE
PRIORITY OVER ALL CONTROLS, REFER TO PUBLICATION
PUB002-057
THE DEFAULT ESD CONFIGURATION IS "STAY PUT", DERIVED
FROM A N/C CONTACT (SIGNAL REMOVED).
FOR OTHER CONFIGURABLE ESD SETTING OPTIONS, REFER TO
PUBLICATION PUB002-057.

Note:
Actuator remote control signals may be internally or externally Internally supplied:
supplied with DC voltage according to wiring diagram. A valid Fit link “#” as shown and connect remote control contacts to
open or close remote control command consists of a control internal supply on terminal 5.
input signal and Motor Enable input signal being applied
simultaneously. Invalid signals will not cause operation Externally supplied:
and will invoke a “MOTOR ENABLE LOSS” alarm on the
Connect control contacts to external supply DC +VE.
display and status relay (make contact). For full status alarm
Connect supply DC-VE to terminal 36 & 31.
conditions refer to PUB002-057.
The Motor Enable and ESD input signals can be configured
to operate in local control. ESD can be user configured for
Stayput, Close or Open. ESD signal must be derived from a
normally closed contact breaking.

10 IQ SIL Option
SIRA Certificate sira
CERTIFICATION

FUNCTIONAL SAFETY CERTIFICATE

This is to certify that the

IQ3 Valve Actuator

manufactured by

Rotork Controls Ltd

(A Division of Rotork PLC)
Brassmill Lane
Bath, BA1 3JQ
UK

have been assessed by Sira Certification Service with reference to the

CASS methodologies and found to meet the requirements of

IEC 61508-2:2010
Routes 1H & 1S
Systematic Capability (SC2)
as an element/subsystem suitable for use in safety related systems performing safety
functions up to and including

SIL 2 capable with HFT = 0 (1oo1)*

SIL 3 capable with HFT = 1 (1oo2)*
when used in accordance with the scope and conditions of this certificate.

* This certificate does not waive the need for further functional safety verification to
establish the achieved Safety Integrity Level (SIL) of the safety related system

Certification Manager:

LY
N
Wayne Thomas

O
Initial Certification : 26 August 2015
This certificate issued : 08 December 2015

T
Renewal date : 25 August 2020

C
This certificate may only be reproduced in its entirety, without any change.

A
TR Sira Certification Service
Part of CSA Group UK

X
Unit 6 Hawarden Industrial Park,

E
Hawarden, CH5 3US, United Kingdom.
Certificate No.: Sira FSP 15001/02 Tel: +44 (0) 1244 670900
Form 7016 issue 5 Email: [email protected]
Page 1 of 10 Web: www.csagroupuk.org

For full certificate see SIRA FSP150001

Keeping the World Flowing 11

Rotork plc
Brassmill Lane, Bath, UK
tel +44 (0)1225 733200
fax +44 (0)1225 333467
email [email protected]

www.rotork.com
Rotork is a corporate
member of the Institute
of Asset Management

As part of a process of on-going product development, Rotork

reserves the right to amend and change specifications without
prior notice. Published data may be subject to change. For the
very latest version release, visit our website at www.rotork.com
The name Rotork is a registered trademark. Rotork recognises
all registered trademarks. The Bluetooth® word mark and logos
are registered trademarks owned by Bluetooth SIG, Inc. and
any use of such marks by Rotork is under license. Published and
produced in the UK by Rotork Controls Limited. POWJB0516

PUB002-104-00 Issue 05/16