Certification Pointek CLS200 · Certification Pointek CLS200 Document Type Certification Report Client Siemens AG PD PA PI R&D PM CRT Oestliche Rheinbrueckenstr. 50 76187 Karlsruhe,

CertificationPointek CLS200

Document Type Certification ReportClient Siemens AG

PD PA PI R&D PM CRTOestliche Rheinbrueckenstr. 5076187 Karlsruhe, Germany

Authors Dipl.-Ing. Wolfgang Velten-PhilippVerifier dr.ir. Michel HoutermansReport 100.210.1 Version 1Status ReleaseDate 2015-02-26

Version Control

Version Date Author Reviewer Description

0 2015-02-07 WVP MH Draft1 2015-02-26 WVP MH Release

©2002-2015 Risknowlogy®

All Rights Reserved

LIMITATION OF LIABILITY-This report was prepared using best efforts. Risknowlogy does not accept any respon-

sibility for omissions or inaccuracies in this report caused by the fact that certain information or documentation was

not made available to us. Any liability in relation to this report is limited to the indemnity as outlined in our Terms

and Conditions. A copy is available at all times upon request. This document is the property of, and is proprietary to

Risknowlogy®. The client has the right to duplicate this document in whole and to distribute it in whole. Third parties

do not have the right to disclose in whole or in part and no portion of this document shall be duplicated by any third

party in any manner for any purpose without Risknowlogy’s expressed written authorisation.

Risknowlogy®, the Risknowlogy logo, Functional Safety Data Sheet®, and Spurious Trip Level® are registered service

marks of Risknowlogy, STL™ is a Risknowlogy trademark.

Report 100.210.1 Version 1 Release page 2 of 12

Contents

1 Introduction 51.1 Objective and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.2 Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.3 Functional Safety Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 Proven In Use Demonstration 72.1 Limited Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.2 Conditions Of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.3 Field Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.4 Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.5 Reliability analysis (FMEDA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.6 EMC, Basic Safety and Environmental Testing . . . . . . . . . . . . . . . . . . . 8

3 User Documentation 9

4 Conclusions 10

5 Standards 11

6 References 11

List of Tables

1 Pointek CLS200 variants for safety related use . . . . . . . . . . . . . . . . . . . 62 Field Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Functional safety data for Pointek CLS200 . . . . . . . . . . . . . . . . . . . . . . 84 PFDG for Pointek CLS200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

List of Figures

1 Pointek CLS200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 PFDG for Pointek CLS200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9


Parties

About Siemens

Siemens offers a comprehensive range of products and systems for process instrumentation andprocess analytics for non safety and safety related applications. The process instrumentationportfolio covers positioners, process instruments for pressure, temperature, flow and level mea-surements. The products for process analytics include continuous gas analysers for stand-aloneand system solutions as well as process gas chromatographs.

About Risknowlogy

Risknowlogy was founded in 2002 and is an employee owned business. We offer products,services, engineering, consulting, certification and training in the field of risk, reliability andsafety. Our offices are located in Argentina, Colombia, Germany, France, India, The Netherlands,Switzerland (HQ), the United Arab Emirates and the United Kingdom.


1 Introduction

1.1 Objective and Scope

The objective of this report is to document the proven in use study carried out for the PointekCLS200 capacitive level switch. Purpose of this proven in use study is to demonstrate that thedevice is suitable to be used in safety instrumented functions up to SIL 2 according to IEC 61511and IEC 61508 [1, 2].

1.2 Product Description

The product subject to the proven in use analysis is the Pointek CLS200 capacitive level switch.The product is shown in Figure 1.

Figure 1: Pointek CLS200

CLS200 is a versatile inverse frequency shift capacitance level switch with optional rod and ca-ble choices with configurable output. It is suitable for detection of liquids, solids, slurries, foamand interfaces. When the measured material approaches or contacts the sensor, an increase incapacitance is sensed and a alarm is triggered.


1.3 Functional Safety Properties

The functional safety properties according to IEC 61508 are:

• Safety function: Level detection by change of capacitance between uncovered and coveredprobe. If the capacity change reaches the set point the relay and solid state output will bede-energised [4]. The set point is a user defined parameter.

• This is a type A device with hardware fault tolerance 0.

• The operation mode is low demand mode.

The following table lists the available CLS200 variants for safety related purposes:

Table 1: Pointek CLS200 variants for safety related use

MLFB-Number

7ML5630-*****-***0 Standard rod with threaded or flanged process connection7ML5631-*****-***0 Cable version with threaded or flanged process connection7ML5632-*****-***0 Standard rod with sanitary process connection7ML5633-*****-***0 Standard sliding coupling with threaded process connection7ML5634-*****-***0 Standard PFA coated rod with PFA coated flanged process connection

Notes:Wildcards above express

• Enclosure and lid

• Approvals

• Probe material

• Wetted seals

• Thermal isolator, remote mount electronics or bracket

• Probe length

• Process Connection


2 Proven In Use Demonstration

2.1 Limited Functionality

The purpose of the instrument is to detect presence of materials by change of the capacity be-tween probe and environment. The functionality is restricted to this measurement.

2.2 Conditions Of Use

The instrument considered for proven in use have been used in similar operating environments[5]. These include more than 10 typical industrial process environments.

2.3 Field Data

Siemens evaluated field data for the instruments since 2010 [5]. From the operating hours ofeach device only 24 month are taken into account. Non operating hours and storage times areconsidered by that approach. The typical operating time in the process industry is assumed 24hours per day. Siemens has compiled customer feedback and repair data [5]. The data wasreviewed by Risknowlogy and demonstrates that during the time under consideration 33 randomfailures have occurred. The reported failures were classified as dangerous.

Table 2: Field Data

Product Operating hours Safe Failures Dangerous Failures

Pointek CLS200 246.376.460 h 1 32

2.4 Modifications

During the time span used for the proven in use demonstration modifications were performedby the manufacturer [6]. The proven in use demonstration includes all hardware modificationssince 2010. All modifications have been reviewed by Risknowlogy to verify that the manufacturerapplied suitable lifecycle measures to avoid systematic failures during the modification process.This includes the product verification after the modification [6]. Furthermore all modifications werereviewed in detail to judge the impact on the product.

The result of the evaluation above is that all hardware modifications are related to product im-provements and component exchange due to supplier changes. The hardware modificationshave no impact on the safety function of the device.


Summarised, the modifications are classified as limited, traceable and minor. All modificationswere subject to regression testing. The modifications are no contradiction for the proven in useverification process. The systematic capability of the device is compliant to route 2H according toIEC 61508-2, SC 2.

2.5 Reliability analysis (FMEDA)

Siemens has carried out a qualitative and quantitative reliability study in line with the require-ments of the IEC 61508 [1] standard. The reliability study consists of a failure modes and effectsanalyses (FMEDA) [7],[3]. Table 3 is presenting the summary of the reliability data derived fromthe FMEDA.

Table 3: Functional safety data for Pointek CLS200

Properties FMEDA Proven In Use 90% Confidence

Type ASafe failure rate 202 4.1 19Safe detected failure rate 0 n.a. n.aSafe undetected failure rate 202 n.a. n.aDangerous failure rate 253 130 174Dangerous detected failure rate 92 n.a. n.aDangerous undetected failure rate 160 n.a. n.aSafe failure fraction 65% n.a. n.a

Notes:Failure rates are in FIT 10−91/h.Confidence interval according to IEC 61508 route 2H.

The mean value derived from the field data is 130 FIT for the dangerous failure rate and 174 FITfor the upper limit taking a 90% confidence interval according IEC 61508-2, route 2H into account.

Table 4 and Figure 2 showing the PFDG results for different proof test intervals. The FMEDAanalysis, which represents design expectations, corresponds with the data from the proven in usedata, which represents operational experience.

2.6 EMC, Basic Safety and Environmental Testing

The product complies [8] with

• EMC directive 2004/108/EC

• ATEX directive 94/9/EC

• LVD directive 2006/95/EC


Table 4: PFDG for Pointek CLS200

Years 1 2 5 10

PFDG 8.8E-4 1.4E-3 3.48E-3 6.93E-3%SIL 2 8.8% 14% 34.8% 69.3%PFSavg 8.8E-4

PFDG values above are worst case values for the configurations shown by table 1.MTTR 8h

Figure 2: PFDG for Pointek CLS200

3 User Documentation

The safety manual [9] provided by Siemens provides all necessary information for use of theproduct. The manual was reviewed without any objections.


4 Conclusions

The proven in use analysis demonstrates that the level sensor Pointek CLS200 corresponds withSIL 2 safety properties according to IEC 61511 and IEC 61508, route 2H.

Risknowlogy Germany GmbH,

Wolfgang Velten-PhilippAuthor

dr.ir. Michel HoutermansVerifier


5 Standards

[1] IEC 61508: 2010Functional safety of electrical/electronic/programmable electronic safety related systems.

[2] IEC 61511: 2003Functional safety: Safety instrumented systems for the process industry sector.

[3] SN29000: 1996Failure Rates of Components.

6 References

[4] 001_CLS200_Analog_SIL2_150213_Rel.

[5] 011_CLS200.HoursInUseReport 2015Jan16012_CLS200.FieldStatistics 2015Jan16013_CLS200_ApplicationOverview r1.

[6] 02Y_Change Management A5E30790455A_015_Rel02Z_Guideline on Impact Analysis A5E31786522A_001021_CLS200 Analog.CP-HW 2015Jan19 .

[7] 051a_FMEDA V6 CLS200_150212_Rel051b_FMEDA V6 CLS200_150212_Cless052_CLS200_FMEDA_MechParts_Rod_150212053_CLS200_FMEDA_MechParts_Cable_150212055_CLS200_FMEDA_MechParts_SlidingC_150212 .

[8] 061_PC2000C0 - CE Declaration062_Old vs New MLFB063_CLS200RMT_MIL494E064_CLS200STD_MIL481C_B065_CLS200STD_MIL481E066_CLS200STD_MIL481F_B .

[9] 071_7ML19985JH04072_A5E35637149_AA_Draft2 .


[10] 031_CLS200_Bom_Structure_150212032_7ML5630A-DESIGN_03_Rel_Drw_Rod033_7ML5631A-DESIGN_03_Rel_Drw_Cable034_7ML5632A-DESIGN_03_Rel_Drw_Sanitary035_7ML5633A-DESIGN_03_Rel_Drw_SlidingC036_7ML5634A-DESIGN_02_Rel_Drw_PFA_Rod .

[11] 041_A5E00296063B-02_Rel_CirDia_Sensor042_A5E00318310B_02_Rel_CirDia_Barrier043_A5E00296050B_03_Rel_Amplifier044_A5E00296059B_02_Rel_CirDia_PowerSupply .


Documents

Certification Pointek CLS200 · Certification Pointek CLS200 Document Type Certification Report Client Siemens AG PD PA PI R&D PM CRT Oestliche Rheinbrueckenstr. 50 76187 Karlsruhe,