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

Presenters 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 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

Introduction 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 Syncade Smart Logic Solver is an Enabler for AMS Device manager and SMART Field Devices 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 SIS Installation & Commissioning [Clause 14] SIS Safety Validation [Clauses 12.3, 12.7 & 15] Install Modification (Change Control) [Clause 17]

SMART 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 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 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 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 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 party schedulers such as SAP or Maximo)

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.

SIS Proof Test Automation Manual Procedure Document Storage Mobile Wireless Worker Complete Accurate Right First Time Error Detection

Safety Life Cycle Summary IEC61511 Wiring checkout and loop tests

Example: Rosemount 3051S proof test procedures

3051S Proof Test using a HART communicator and mA meter

3051S Proof Test using DeltaV SIS

Perform the abbreviated loop test directly from DeltaV Explorer

DeltaV SIS internal values are verified using diagnostics & engineering tools.

3051S Proof Test Procedure using Syncade Electronic Workflow Manual step performed by technician in field.

Electronic Work Instruction Scheduling

Portal personalized for the Technician

Training Records Prevent Unauthorized Execution

Electronic Work Instruction Execution

Electronic Work Instruction Configuration

Electronic Work Instruction Reporting

Interlock 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.

Summary Task Analysis - BEFORE Wiring checkout and loop test Proof testing

Interlock Proof Check – After Acknowledging the alarm. Graphics show that the valves have tripped. Entering manual entry into AMS Audit Trail. 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 – AFTER Wiring checkout and loop test Proof testing

Business Results Achieved Profit Cost $ time before after Faster Commissioning Faster wiring checkout and loop checks Automated documentation Cost reduction Reduced manpower costs  Faster time-to profit 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 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 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 30 th 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

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