Safety System Simulation : Using the Virtual Process Link with Prosafe RS

Transcription

1 2006 & Technology Fair Safety System Simulation : Using the Virtual Process Link with Prosafe RS Winston Jenks / Cedric Oudinot Technical Dir / Marketing Mgr November 28, 2006 Company Logo

2 A word about Cape Software Privately owned software company HQ in Houston, TX Over 15 years of experience in the process simulation arena delivering high quality process models Three Products: VP Link ( Operator Training) i ) Test Compiler ( Logic Validation) XP TrendCorder ( Hi-speed process trending & archiving) End users from: Oil and Gas Chemicals Pharmaceuticals Integrators Page 2

3 What are we trying to do? Provide tools to improve FAT execution 21 st Century Software version of HW panel Multi-user interface allows teams to work simultaneously Can check logic/communication in multi-vendor systems Provide value for the customer during Safety Lifecycle Adhere to OSHA and IEC Testing Standards Use a Structured Test Procedure Test Procedure generates documentation and Test Scripts Running the tests produces electronic test logs Stored tests are run periodically to revalidate logic Enable integrated training with DCS Page 3

4 What is Process S(t)imulation A dynamic representation of a complex process to an offline control system Engineering Workstation Read value of outputs Write simulated inputs VP Link Server Calculate Process Variables Page 4

5 VP Link / Prosafe RS Interface Extraction Utility builds VP Link database Non-invasive Positively No change to safety application Connects at the I/O level to allow for full functional testing Connects to : real controller Emulated PC controller ( Simulation Mode) No limits on number of points or controllers Logic Validation with VP Link on Prosafe RS Page 5

6 VP Link / Prosafe RS Interface Test Types Logic Validation with VP Link on Prosafe RS Page 6

7 VP Link / Prosafe RS Interface VP Link Connection Logic Validation with VP Link on Prosafe RS Page 7

8 VP Link / Prosafe RS Interface Virtual Test mode Security None required Locking Input locking not required, I/O is not connected Internal variable locking is required Data Source Inputs -- Logical values are written Outputs -- Logical values are read Logic Validation with VP Link on Prosafe RS Page 8

9 VP Link / Prosafe RS Interface Target Test Mode I/O values are forced Normal security of Prosafe is enforced on SCS Logic Validation with VP Link on Prosafe RS Page 9

10 V-Approach methodology: towards error-free safety logic on a new project Safety Requirement Spec Narrative Pre Start-Up Safety Review Run manual Tests Cause & Effect Develop Scenarios Function Block Design Black Box Testing Deliverable Verification Functional Logic Logic Validation with VP Link on Prosafe RS Page 10

11 I have a functional SIS already! OSHA 29 CFR Part 1910 Emergency Shutdown systems : Document each inspection and test, including: -Date of test -Name of person who performed dthe test t [..] -Description of test results Our Answer? IEC : Periodic proof test shall be conducted using a written procedure to reveal undetected faults Test Compiler IEC Part 1,7.18: Information on the verification activities shall be collected and documented as evidence that the phase being verified has, in all respects, been satisfactorily completed. Part 1,7.14 :Documentation for validation shall include: -Activities iti in chronological l order -Discrepancies between expected and actual results Logic Validation with VP Link on Prosafe RS Page 11

12 VP Link Test Compiler Generates Test Scripts, using an Excel front-end Scripts Based on User Test Plan and Functional Specifications A Script is a stand alone entity that AUTOMATICALLY : Forces inputs to a specified Statet Compares the outputs to the expected state table ( Cause and Effect Matrix) Logs errors to HTML format Runs and documents entire test plan unattended Results Summarizer utility Scenario Template Generator Page 12

13 Test Compiler Input Format Similar to a Cause and Effect Matrix Verify ALL output changes, not just one prescribed by test High Level language and keywords for maximum flexibility Sequence Interlocks / SD / Fire & Gas Page 13

14 Test Compiler output (1): Documentation Source HTML Test description Global Parameters Scenario Steps D:\tb40\Books\Refinery\BMS.xls[templates] Documentation created: Jun 19, 2003 at 13:08 Source File: D:\tb40\Books\refinery[template] last modified Jun 19, 2003 at 13:03 History Purpose: This scenario will: Start Heater Purge and Verify Purge Completion VP Database: This scenario is designed to run with the database in refinery_5.cfg. Click on these links for the list of input and output tags. If this scenario was built from a template, then the tags will be listed, but they will be marked as "not found". Defaults: The standard delay inserted before values are checked is 0 seconds for this scenario. The relative tolerance used in the test for equality is %. Values in SET_HI and SET_LO commands are set 1 units above or below the alarm value uespecified edin the Excel sheet. Scenario Actions: Turn i17hs0669b OFF, Field Trip for Heater Line 4(Row 6): Set i17hs0669b to the OFF state. Set i17xsc1971 to the OFF state. Wait for seconds beyond the standard delay before continuing. Line 5(Row 7): Set i17hs0669b to the ON state. Set i17xsc1971 to the ON state. Get Heater Ready to Purge Set Level i17lt1641 to 10 Line 8(Row 10): Set i17lt1641 to 10. Database ETC. Page 14

15 Test Compiler output (2): Test Result Log Scenario Log Sample Time stamps Assertion passed Assertion Failed 0 Starting test 'D:\TB40\BOOKS\FLINT\PLC5\H1_BRNR.SCE' at Wed May 28 18:23: # 1181 # 17H-1 Start Main Burner Sequence 1181 # Satisfy and Reset Fuel Gas Trip 1181 # Turn i17hs1964, i17hs1964a ON to Satisfy FG Trip 5397 # Turn i17hs1964rst ON to Reset FG Trip 9614 # Turn i17hs1923 ON to Start t Main Burner # Test at line 10 of 'H1_BRNR.SCE' ON i17hs Verification <i17xy1904> = passed **Verification <i17xy2419> = FAILED Value is Verification <i17yl1906> = passed Verification <i17xy1907> = passed Verification <i17yl1921> = passed # Closing test log after 0 mins 13.8 secs at Wed May 28 18:24: Starting test 'D:\TB40\BOOKS\FLINT\PLC5\H1_BRNR.SCE' at Wed May 28 18:26: # 851 # 17H-1 Start Main Burner Sequence 851 # Satisfy and Reset Fuel Gas Trip Page 15

16 Case Study BASF Site 7 SIS systems Running for 5 years Upcoming turnaround, needs to revalidate all logic SIS up to specs User led Cost Analysis study between: Option 1: Manual re-certification ( considering C&E/documentations not up to date), including man-hours only (no resource constraint) Option 2: Automating entire test plan using Test Compiler Results: Option 1: not feasible, 10% costlier than option 2 and one-shot Option 2: Independent third party validation Reusable change management tool for periodic testing Fully Automated Always Up to date Test Plan Page 16

17 Conclusion VP Link is a proven in-use solution for logic validation It is cross platform (DCS/PLC/SIS) Quadlog CS3000 ProsafeRS It is easy to use, learn and maintain (graphic oriented) Test Compiler makes compliance with IEC & a PLANT REALITY Versatile, VP Link is also used for Operator Training High-fidelity simulation blocks available Trainee performance assessment module Actual graphics/control applications used in native control environment Low Total Cost of Ownership Page 17

18 Backup BACK-UP SLIDES Logic Validation with VP Link on Prosafe RS Page 18

19 Simulation Screen Shots Automated Tag sheet Input/Output sheets per ESD HMI for advanced testing or training i Page 19

20 VP Link for Yokogawa CS3000 / Prosafe RS Trainer Station VP Link/ CS3000 Interface Exa OPC Server with VP3 driver VP Link/RS Redundant Interface Ethernet /V-Net ProSafe RS Controller or emulated FCS Controllers (or emulated in Test Function) Page 20 HIS Trainee Station

21 VP Link for Yokogawa CS3000 / Prosafe RS VP Link Driver allows you to set the locking strategy depending on which target you use Page 21

22 VP Link for Yokogawa CS3000 / Prosafe RS Don t need to force variables when running in Virtual Test mode Page 22

23 VP Link for Yokogawa CS3000 / Prosafe RS VP Link reads/writes the Logical Value Page 23