using syncade workflow and ams device manager for sif proof testing on a deltav smart sis system
DESCRIPTION
Presented at Emerson Exchange 2010 in San Antonio, Texas by Proconex' Ed Smigo. Won award for best in track presentation.TRANSCRIPT
Using Syncade Workflow and AMS Device Manager for SIF Proof Testing on a DeltaV SMART SIS System
Using Syncade Workflow and AMS Device Manager for SIF Proof Testing on a DeltaV SMART SIS System
Ed Smigo Director Systems Technology
PresentersPresenters
Ed Smigo
Thirty three years in the process controls industry, the last 30 for PROCONEX a Local Business Partner
for Emerson Process Management n the Philadelphia territory. Early focus on process automation with
analog and DCS controls, more recently focused on Digital Instrumentation, Fieldbus Technologies,
Asset Management and Reliability systems in coordination with business and financial impact through
data visualization through OEE (Overall Equipment Effectiveness) dashboards.
Past Education Chair for ISA District II
Bachelor of Science Electrical Engineering Technology Pennsylvania State University.
EIT Certificate State of Pennsylvania
AICHE Paper Published on Fieldbus Technologies
Process Manufacturers Constantly Strive to Improve Their Business Performance Process Manufacturers Constantly Strive to Improve Their Business Performance
The industry faces dynamic business conditions Global Competition Creates Cost Pressures Efficiently And Safely Operate New Facilities In Emerging Markets
With A Less Experienced Workforce Improve Profitability By Reducing Inventory, Managing Product
Changes, And Increasing Capacity Meet Changing Regulations And Sustainability Goals Retain Knowledge
IntroductionIntroduction
IEC 61511 defines good engineering for work practices and documentation of Safety Systems. This paper
focus on how SMART Instruments coupled with SMART Logic Solver and software tools can facilitate an
automated test and documentation process. We will discuss:
SMART HART Instruments SMART Logic Solvers Asset Management Solutions and associated Snap-on’s Workflow applications to guide and document
DeltaV Smart SIS with AMS QuickCheck and SyncadeDeltaV Smart SIS with AMS QuickCheck and Syncade
Smart Logic Solver is an Enabler for AMS Device manager and SMART Field Devices
Smart Logic Solver is an Enabler for AMS Device manager and SMART Field Devices
•SIS Installation & Commissioning•[Clause 14]
•SIS Safety Validation•[Clauses 12.3, 12.7 & 15]
Install
•M
od
ific
atio
n (
Ch
ang
e C
on
tro
l)•
[Cla
use
17]
• Satisfy IEC 61511 Standard for…
• Commissioning• Validation• Change Control• Documentation• On going Proof Tests
• Perform Wiring Infrastructure Check Non Intrusively with actual field devices
• Eliminate Wiring errors
• Test for…..• Loose
connections• Corrosion• Instrumentation
Issues• Can test through
voting logic
SMART HART InstrumentsSMART HART Instruments
SMART HART Instruments provide the enabling infrastructure to allow automated testing and electronic data recording
Emerson HART instruments support “Methods” that allow the instrument to take on the function of a signal generator
Sensor testing optionsSensor testing options
Safely test the SIF using actual process
variables
Test sensors in-situ by other means
Perform wiring continuity test
Remove sensor and test on bench
Use smart features to test electronics
and wiring continuity
SMART Logic SolversSMART Logic Solvers
Provide the communications channel between the testing software and the field instrument to facilitate the automatic testing
SMART logic solvers can be locked to prevent unauthorized tests while the plant is in operation
SMART logic solvers can leverage other diagnostic capability of SMART HART field instruments that can increase availability without sacrificing safety
AMS with Syncade WorkflowAMS with Syncade Workflow
AMS through its snap-on interface allows built for purpose snap-ons to execute the HART “Methods” down through the on-line systems interface to the field device
The QuickCheck snap-on, through a web services interface becomes a conduit for any automated work flow steps from Syncade. (Steps are created in Syncade rather than QuickCheck)
Extends PlantWeb into Operations Management
Process Control for the “Work People Do”
Delivers Streamlining and Efficiency for Work Practices
Provides Basis for Electronically Integrated Enterprise
Business Results with SyncadeBusiness Results with Syncade
Syncade workflow behaviors can be configured to guide the tester through the manual steps as well as executing the automated steps eliminating errors due to misinterpretation of paper work flow.
Syncade DCA records manual interactions and results from automated steps; electronically captured for reporting purposes ensuring data integrity
The Syncade Training module maintains personnel training records; only a person trained for a task can execute it means it is done right the first time.
The Syncade ET Module can handle all proof test scheduling. Scheduling can alert personnel automatically or can be reviewed at will in the event an unplanned outage permits one to do proof tests ahead of schedule. Smart use of resources allows more work to be completed during a scheduled outage increasing efficiency. (Syncade can also interface with third partyschedulers such as SAP or Maximo)
What would we like to achieve?What would we like to achieve?
Guide the technician through each step with paperless electronic work instructions
Automatic documentation of work performed. Automated error detection. Confirmation that test values are within tolerance. Proof test library with standard procedures. Can be used on a desktop, laptop, or with wireless
hand-held devices.
Where is Your Paper??Where is Your Paper??
Kill off the ClipboardKill off the Clipboard
Get on the Wireless TerminalGet on the Wireless Terminal
SIS Proof Test AutomationSIS Proof Test Automation
Manual Procedure
Document Storage
Mobile Wireless Worker
Complete Accurate Right First Time Error Detection
[File Name or Event]Emerson Confidential27-Jun-01, Slide 16
Safety Life Cycle Summary IEC61511Safety Life Cycle Summary IEC61511Safety Life Cycle Summary IEC61511Safety Life Cycle Summary IEC61511
Wiring checkout and
loop tests
Example: Rosemount 3051S proof test proceduresExample: Rosemount 3051S proof test procedures
3051S Proof Test using a HART communicator and mA meter3051S Proof Test using a HART communicator and mA meter
3051S Proof Test using DeltaV SIS3051S Proof Test using DeltaV SIS
[File Name or Event]Emerson Confidential27-Jun-01, Slide 20
Perform the abbreviated loop test Perform the abbreviated loop test directly from DeltaV Explorerdirectly from DeltaV ExplorerPerform the abbreviated loop test Perform the abbreviated loop test directly from DeltaV Explorerdirectly from DeltaV Explorer
[File Name or Event]Emerson Confidential27-Jun-01, Slide 21
DeltaV SIS internal values are verified DeltaV SIS internal values are verified using diagnostics & engineering tools.using diagnostics & engineering tools.DeltaV SIS internal values are verified DeltaV SIS internal values are verified using diagnostics & engineering tools.using diagnostics & engineering tools.
[File Name or Event]Emerson Confidential27-Jun-01, Slide 22
DeltaV SIS internal values are verified DeltaV SIS internal values are verified using diagnostics & engineering tools.using diagnostics & engineering tools.DeltaV SIS internal values are verified DeltaV SIS internal values are verified using diagnostics & engineering tools.using diagnostics & engineering tools.
[File Name or Event]Emerson Confidential27-Jun-01, Slide 23
DeltaV SIS internal values are verified DeltaV SIS internal values are verified using diagnostics & engineering tools.using diagnostics & engineering tools.DeltaV SIS internal values are verified DeltaV SIS internal values are verified using diagnostics & engineering tools.using diagnostics & engineering tools.
[File Name or Event]Emerson Confidential27-Jun-01, Slide 24
DeltaV SIS internal values are verified DeltaV SIS internal values are verified using diagnostics & engineering tools.using diagnostics & engineering tools.DeltaV SIS internal values are verified DeltaV SIS internal values are verified using diagnostics & engineering tools.using diagnostics & engineering tools.
3051S Proof Test Procedureusing Syncade Electronic Workflow3051S Proof Test Procedureusing Syncade Electronic Workflow
Manual step performed by technician in field.
[File Name or Event]Emerson Confidential27-Jun-01, Slide 26
Electronic Work Instruction SchedulingElectronic Work Instruction Scheduling
[File Name or Event]Emerson Confidential27-Jun-01, Slide 27
Portal personalized for the TechnicianPortal personalized for the Technician
[File Name or Event]Emerson Confidential27-Jun-01, Slide 28
Training Records Prevent Unauthorized ExecutionTraining Records Prevent Unauthorized Execution
[File Name or Event]Emerson Confidential27-Jun-01, Slide 29
Electronic Work Instruction ExecutionElectronic Work Instruction Execution
[File Name or Event]Emerson Confidential27-Jun-01, Slide 30
Electronic Work Instruction ExecutionElectronic Work Instruction Execution
[File Name or Event]Emerson Confidential27-Jun-01, Slide 31
Electronic Work Instruction ExecutionElectronic Work Instruction Execution
Electronic Work Instruction ConfigurationElectronic Work Instruction Configuration
[File Name or Event]Emerson Confidential27-Jun-01, Slide 33
Electronic Work Instruction ReportingElectronic Work Instruction Reporting
Interlock proof test - BEFOREInterlock proof test - BEFORE
Alright Bob, go ahead and return PT-102 to normal
pressure.
Ian, can you verify that XV-105 and XV-106 have
closed as a result of this trip?
Ian, can you verify that XV-105 and XV-106 have
closed as a result of this trip?
We’re going to test the T-200 high pressure shutdown SIF.
Bob, go to PT-101. It is on top of T-200.
Acknowledging the alarm. Graphics show that the
valves have tripped.
Acknowledging the alarm. Graphics show that the
valves have tripped.
Trip cleared. Resetting the
SIF and initialing paperwork.
Trip cleared. Resetting the SIF and signing off on
the paperwork.
Pump up the pressure on the sensor to the trip point of 120 psig.
Bob, pump up the pressure on the sensor to the trip point of 120 psig.
Alright Bob, go ahead and return PT-101 to normal
pressure and move over to PT-102.
Whistling….XV-106 tripped. Let me check XV-105.
XV-106 tripped too. Both valves are
closed.
Hooking up the test equipment to
PT-101
The pressure value should be about 121
psig.Found it.The pressure value should be about 121
psig.
XV-105 tripped. Let me check XV-106.
XV-105 tripped too. Both valves are
closed.
PT-102 is back to normal.
I’m hooked up to PT-102 now.
[File Name or Event]Emerson Confidential27-Jun-01, Slide 35
Summary Task Analysis - Summary Task Analysis - BEFOREBEFORESummary Task Analysis - Summary Task Analysis - BEFOREBEFORE
Wiring checkout and loop test
Proof testing
Acknowledging the alarm. Graphics show that the
valves have tripped. Entering manual entry into
AMS Audit Trail.
Interlock Proof Check – AfterInterlock Proof Check – After
PT-101 – send 120 psig signal.
PT-102 – send 120 psig signal.
PT-101 – return to
normal service.
PT-102 – return to
normal service.
Trip cleared. Resetting the SIF.
That was easy!
Confirmed that XV-105 and XV-106 are
reset (open) via HART.
QuickCheck and the QuickStep
feature is all set up. Start…. <click>
Confirmed that XV-105 and XV-106 are
closed via HART.
PT-101 returned to normal service.Sending 120 psig signal.
XV-105 is
closed. XV-106 is
closed.XV-105 is open.
XV-106 is open.
Sending 120 psig signal.
PT-102 returned to normal service.
[File Name or Event]Emerson Confidential27-Jun-01, Slide 37
Summary Task Analysis – Summary Task Analysis – AFTERAFTERSummary Task Analysis – Summary Task Analysis – AFTERAFTERWiring checkout and loop test
Proof testing
Business Results AchievedBusiness Results AchievedP
rofit
Cos
t
$time
Faster time-to profit
before
after
Faster Commissioning Faster wiring checkout and loop checks Automated documentation
Cost reduction Reduced manpower costs
Reduction in manpower:
40 min x 2 techs = 80 min
20 min x 1 tech = 20 min
80 min – 20 min = 1 MH
300 devices x 1 MH
= 300 MH (~ 7 weeks)
Reduced cost
Integrated safety lifecycle managementIntegrated safety lifecycle management
• Hazard analysis• LOPA• Safety requirement
specification
• SIL Verification• Spares analysis
• Reliability analysis• Production analysis• Performance analysis• Cost of unreliability• Integration with ERP
• Document control• Document repository• Management of change
• Document control• Document repository• Management of change
• Document management• Proof tests workflow• Proof test reports
• Device management• Device configuration• Device calibration\• Electronic loop tests
• Engineering tools• Simulation / testing• Management of change
• SIF execution• Event recording• Bypassing/overrides• Management of change
• Smart Pressure• Smart Temperature• Smart Level• Smart Flow• DVC6000 SIS
• Device management• Device configuration• Device calibration• Electronic loop tests
Where To Get More InformationWhere To Get More Information
Safety Life Cycle Management Technology Forum– Monday, September 27 from 3:00 to 4:00PM CDT– Wednesday, September 29 from 1:15 to 2:15PM CDT
DeltaV SIS Roadmap– Wednesday, September 29 from 11:00 to 12:00PM CDT– Wednesday, September 29 from 1:15 to 2:15PM CDT
Syncade Suite Overview– Thursday September 30 from 1:15 – 5:15 CDT
Syncade integration Architecture– Thursday September 30th from 3:15 – 4:00
Syncade SIS Workflow Demonstrations– Event Floor September 27, 28 and 29