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

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


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


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.


Electronic Work Instruction SchedulingElectronic Work Instruction Scheduling


Portal personalized for the TechnicianPortal personalized for the Technician


Training Records Prevent Unauthorized ExecutionTraining Records Prevent Unauthorized Execution


Electronic Work Instruction ExecutionElectronic Work Instruction Execution

Electronic Work Instruction ConfigurationElectronic Work Instruction Configuration


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.


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.


Summary Task Analysis - Summary Task Analysis - BEFOREBEFORESummary Task Analysis - Summary Task Analysis - BEFOREBEFORE

Wiring checkout and loop test

Proof testing


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.


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

Using Syncade Workflow and AMS Device Manager for SIF Proof Testing on a DeltaV SMART SIS System

Education

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