Gwajin shaida wani muhimmin sashi ne na kiyaye amincin tsarin kayan aikin mu na aminci (SIS) da tsarin da ke da alaƙa (misali ƙararrawa mai mahimmanci, tsarin wuta & gas, tsarin kulle kayan aiki, da sauransu). Gwajin shaida gwaji ne na lokaci-lokaci don gano gazawar haɗari, gwada aikin da ke da aminci (misali sake saiti, kewayawa, ƙararrawa, bincike, rufewar hannu, da sauransu), da tabbatar da tsarin ya cika ƙa'idodin kamfani da na waje. Sakamakon gwaje-gwajen shaida kuma ma'auni ne na tasiri na shirin amincin injinan SIS da amincin filin na tsarin.
Hanyoyin gwaji sun ƙunshi matakan gwaji daga samun izini, yin sanarwa da kuma cire tsarin daga sabis don gwaji don tabbatar da cikakken gwaji, rubuta gwajin gwaji da sakamakonsa, mayar da tsarin aiki, da kimanta sakamakon gwajin na yanzu da kuma shaidar da ta gabata. sakamakon gwaji.
ANSI/ISA/IEC 61511-1, Sashe na 16, ya ƙunshi gwajin shaidar SIS. Rahoton fasaha na ISA TR84.00.03 - "Ingantacciyar Injiniya na Tsarin Kayan Aiki na Tsaro (SIS)," ya rufe gwajin shaida kuma a halin yanzu ana kan bita tare da sabon sigar da ake tsammanin fitowa nan ba da jimawa ba. Rahoton fasaha na ISA TR96.05.02 - "Gwajin Tabbacin Wurin Wuta na Wuta Mai sarrafa kansa" a halin yanzu yana kan haɓakawa.
Rahoton HSE na UK CRR 428/2002 - "Ka'idoji don gwajin gwaji na kayan aikin aminci a cikin masana'antar sinadarai" yana ba da bayani game da gwajin gwaji da abin da kamfanoni ke yi a Burtaniya.
Hanyar gwajin hujja ta dogara ne akan nazarin sanannun hanyoyin gazawar haɗari ga kowane ɗayan abubuwan da ke cikin hanyar tafiya ta kayan aikin aminci (SIF), aikin SIF azaman tsarin, da kuma ta yaya (kuma idan) don gwada gazawar haɗari mai haɗari. yanayin. Haɓaka tsarin ya kamata a fara a cikin tsarin ƙirar SIF tare da ƙirar tsarin, zaɓin abubuwan da aka gyara, da ƙaddara lokacin da kuma yadda za a gwada gwajin. Kayan aikin SIS suna da nau'o'i daban-daban na wahalar gwaji waɗanda dole ne a yi la'akari da su a cikin ƙirar SIF, aiki da kiyayewa. Misali, mitoci da masu watsa matsi sun fi sauƙi don gwadawa fiye da na'urorin motsa jiki na Coriolis, mita magn ko firikwensin matakin radar ta iska. Aikace-aikacen da ƙira ɗin bawul ɗin kuma na iya yin tasiri ga cikakkiyar gwajin tabbacin bawul don tabbatar da cewa gazawar haɗari da haɓakawa saboda lalacewa, toshewa ko gazawar dogaro da lokaci ba sa haifar da gazawa mai mahimmanci a cikin tazarar gwajin da aka zaɓa.
Yayin da ake haɓaka hanyoyin gwajin shaida a lokacin aikin injiniya na SIF, ya kamata kuma a duba su ta wurin Hukumar Fasaha ta SIS, Ayyuka da ƙwararrun kayan aikin da za su yi gwajin. Hakanan ya kamata a yi nazarin lafiyar aiki (JSA). Yana da mahimmanci don samun siyan shuka akan irin gwaje-gwajen da za a yi da lokacin, da yuwuwarsu ta zahiri da aminci. Misali, ba shi da kyau a tantance gwajin juzu'i lokacin da rukunin Ayyuka ba za su yarda da yin shi ba. Hakanan ana ba da shawarar cewa ƙwararrun batutuwa masu zaman kansu (SME) su sake duba hanyoyin gwajin shaida. Gwajin gwaji na yau da kullun da ake buƙata don cikakken gwajin tabbacin aiki an kwatanta shi a hoto na 1.
Bukatun gwajin aikin cikakken aikin Hoto 1: Cikakken ƙayyadaddun ƙayyadaddun gwajin aikin don aikin kayan aikin aminci (SIF) da tsarin kayan aikin aminci (SIS) ya kamata ya bayya ko duba matakan da ke cikin jere daga shirye-shiryen gwaji da hanyoyin gwaji zuwa sanarwa da takaddun shaida. .
Hoto 1: Cikakken ƙayyadaddun ƙayyadaddun shaida na aikin aiki don aikin kayan aikin aminci (SIF) da tsarin sa kayan aikin aminci (SIS) yakamata ya rubuta ko duba matakan da ke jere daga shirye-shiryen gwaji da hanyoyin gwaji zuwa sanarwa da takaddun shaida.
Gwajin tabbatarwa shiri ne na kulawa wanda ya kamata ƙwararrun ma'aikatan da aka horar da su a gwajin SIS, hanyar tabbatarwa, da madaukai na SIS da za su gwada. Ya kamata a yi tafiya ta hanyar kafin yin gwajin shaida na farko, da kuma martani ga Hukumar Fasaha ta SIS daga baya don ingantawa ko gyara.
Akwai hanyoyi guda biyu na rashin nasara na farko (aminci ko haɗari), waɗanda aka raba su zuwa hanyoyi huɗu-masu haɗari waɗanda ba a gano su ba, an gano haɗari (ta hanyar bincike), amintaccen rashin ganowa da amintaccen gano. Ana amfani da sharuddan gazawa masu haɗari da haɗari waɗanda ba a gano su ba a cikin wannan labarin.
A cikin gwajin hujja na SIF, muna da sha'awar farko ga yanayin gazawar da ba a gano ba, amma idan akwai binciken mai amfani da ke gano gazawar haɗari, waɗannan binciken yakamata a gwada su. Lura cewa sabanin binciken mai amfani, bincike na cikin na'urar yawanci ba za a iya inganta shi azaman mai amfani ba, kuma wannan na iya rinjayar falsafar gwajin hujja. Lokacin da aka ɗauki ƙididdige ƙididdigewa na SIL, ƙararrawar ganowa (misali ƙararrawa marasa iyaka) ya kamata a gwada azaman ɓangaren gwajin shaida.
Za'a iya raba hanyoyin gazawa zuwa waɗanda aka gwada yayin gwajin hujja, waɗanda ba a gwada su ba, da gazawar da aka fara ko gazawar da ta dogara da lokaci. Wasu hanyoyin gazawa masu haɗari ƙila ba za a gwada su kai tsaye ba saboda dalilai daban-daban (misali wahala, aikin injiniya ko yanke shawara, jahilci, rashin ƙwarewa, tsallake ko kurakurai na tsari, ƙarancin yuwuwar faruwa, da sauransu). Idan akwai sanannun yanayin gazawar da ba za a gwada su ba, ya kamata a yi diyya a ƙirar na'urar, tsarin gwaji, maye gurbin na'urar lokaci-lokaci ko sake ginawa, da/ko gwajin ƙima ya kamata a yi don rage tasirin SIF na rashin gwaji.
Rashin gazawar farko yanayi ne ko yanayin ƙasƙantar da kai wanda za a iya sa ran gazawa mai hatsarin gaske ta faru idan ba a ɗauki matakan gyara ba a kan lokaci. Yawanci ana gano su ta hanyar kwatankwacin aiki zuwa kwanan nan ko gwajin gwaji na farko (misali sa hannun bawul ko lokutan amsa bawul) ko ta dubawa (misali tashar tashar da aka toshe). Rashin lalacewa ya dogara da lokaci akai-akai - yayin da na'urar ko haɗuwa ke aiki, ƙara ƙasƙanta ta zama; yanayin da ke sauƙaƙe gazawar bazuwar ya zama mai yuwuwa, aiwatar da toshe tashar jiragen ruwa ko gina firikwensin na tsawon lokaci, rayuwa mai amfani ta ƙare, da dai sauransu. Saboda haka, tsawon lokacin gwajin shaida, mafi yuwuwar gazawar haɓakawa ko dogaro da lokaci. Duk wani kariya daga gazawar farko shima dole ne a gwada shi (tsaftacewa tashar jiragen ruwa, gano zafi, da sauransu).
Dole ne a rubuta hanyoyin da za a gwada gwaji don gazawar haɗari (ba a gano) ba. Yanayin gazawa da nazarin sakamako (FMEA) ko yanayin gazawa, tasiri da fasahar bincike (FMEDA) na iya taimakawa gano gazawar da ba a gano masu haɗari ba, kuma inda dole ne a inganta ɗaukar hoto na gwaji.
Yawancin hanyoyin gwajin shaida an rubuta su bisa gogewa da samfuri daga hanyoyin da ake da su. Sabbin hanyoyin da SIFs masu rikitarwa suna kira don ƙarin ingantacciyar hanyar yin amfani da FMEA/FMEDA don bincikar gazawar haɗari, ƙayyade yadda hanyar gwajin za ta gwada ko ba za ta gwada waɗannan gazawar ba, da ɗaukar gwaje-gwajen. Ana nuna zane-zanen toshe ƙayyadaddun yanayin gazawar matakin macro don firikwensin a Hoto na 2. FMEA yawanci yana buƙatar yin sau ɗaya kawai don takamaiman nau'in na'ura kuma a sake amfani da shi don makamantan na'urori tare da la'akari da sabis ɗin tsarin su, shigarwa da damar gwajin rukunin yanar gizon. .
Binciken gazawar macro-Level Hoto 2: Wannan macro-matakin gazawar yanayin bincike toshe zane don na'urar firikwensin da mai watsa matsa lamba (PT) yana nuna manyan ayyuka waɗanda galibi za a tarwatsa su cikin ƙididdigar gazawar micro da yawa don bayyana cikakkiyar gazawar da za a magance. a cikin gwajin aikin.
Hoto 2: Wannan macro-matakin gazawar yanayin bincike toshe zane don na'urar firikwensin da mai watsa matsa lamba (PT) yana nuna manyan ayyuka waɗanda galibi za a rushe su cikin ƙididdigar gazawar ƙananan ƙananan ƙananan don cikakken ayyana yuwuwar gazawar da za a magance a cikin gwajin aikin.
Adadin sanannun, haɗari, gazawar da ba a gano ba waɗanda aka gwada su ana kiran su da ɗaukar hoto na proof (PTC). Ana amfani da PTC a cikin lissafin SIL don "raba" don gazawar don ƙarin gwada SIF. Mutane suna da kuskuren imani cewa saboda sunyi la'akari da rashin gwajin gwaji a cikin lissafin SIL, sun tsara SIF mai dogara. Gaskiya mai sauƙi ita ce, idan ɗaukar gwajin gwajin ku ya kasance 75%, kuma idan kun ƙididdige wannan lambar a cikin lissafin SIL ɗin ku kuma gwada abubuwan da kuke gwadawa akai-akai, 25% na gazawar haɗari na iya faruwa a ƙididdiga. Na tabbata ba na son zama cikin wannan 25%.
Rahoton amincewar FMDA da ƙa'idodin aminci don na'urori yawanci suna ba da mafi ƙarancin tsarin gwajin hujja da ɗaukar hoto. Waɗannan suna ba da jagora kawai, ba duk matakan gwajin da ake buƙata don cikakkiyar hanyar gwajin hujja ba. Sauran nau'ikan bincike na gazawa, kamar binciken bishiyar kuskure da kiyaye tushen dogaro, ana kuma amfani da su don tantance gazawar haɗari.
Za a iya raba gwaje-gwajen tabbaci zuwa cikakken aiki (ƙarshe-zuwa-ƙarshe) ko gwajin aikin ɓangarori (Hoto na 3). Ana yin gwajin aikin ɓangarori da yawa lokacin da sassan SIF ke da tazarar gwaji daban-daban a cikin lissafin SIL waɗanda ba su yi layi tare da rufewa ko juyawa ba. Yana da mahimmanci cewa hanyoyin gwajin shaidar aikin ɓangarori su zo kan juna ta yadda tare za su gwada duk aikin aminci na SIF. Tare da gwajin aikin ɗan adam, har yanzu ana ba da shawarar cewa SIF ta sami gwajin shaida na farko-zuwa-ƙarshe, da waɗanda ke gaba yayin juyawa.
Gwaje-gwajen shaida na ɓangarori yakamata a haɗa hoto na 3: Haɗaɗɗen gwaje-gwajen hujja na ɓangaren (ƙasa) yakamata su rufe duk ayyukan cikakken gwajin shaida na aiki (saman).
Hoto na 3: Haɗaɗɗen gwaje-gwajen shaida na ɓangaren (ƙasa) yakamata su rufe duk ayyukan aikin cikakken gwajin aikin (saman).
Gwajin shaida na ɓangarori kawai yana gwada kashi na yanayin gazawar na'urar. Misali na yau da kullun shine gwajin bawul ɗin bugun jini, inda aka motsa bawul ɗin kaɗan (10-20%) don tabbatar da cewa ba a makale ba. Wannan yana da ƙaramin ɗaukar hoto fiye da gwajin shaida a tazarar gwaji na farko.
Hanyoyin gwaji na tabbacin na iya bambanta da rikitarwa tare da sarkar SIF da falsafar gwajin tsarin kamfani. Wasu kamfanoni suna rubuta dalla-dalla matakan gwajin mataki-mataki, yayin da wasu suna da gajerun hanyoyi. Ana amfani da nassoshi zuwa wasu hanyoyin, kamar daidaitaccen daidaitawa, wani lokaci ana amfani da su don rage girman tsarin gwajin hujja kuma don taimakawa tabbatar da daidaito a gwaji. Kyakkyawan tsarin gwajin shaida yakamata ya ba da cikakkun bayanai don tabbatar da cewa duk gwajin ya cika kuma an rubuta shi, amma ba dalla-dalla ba don sa masu fasaha su so su tsallake matakai. Samun ma'aikacin, wanda ke da alhakin aiwatar da matakin gwajin, farkon matakin gwajin da aka kammala zai iya taimakawa wajen tabbatar da cewa za a yi gwajin daidai. Sa hannu kan kammala gwajin shaida ta mai kula da kayan aiki da wakilan ayyuka kuma za su jaddada mahimmanci da tabbatar da kammala gwajin shaida yadda ya kamata.
Ya kamata a koyaushe a gayyace ra'ayoyin ƙwararru don taimakawa inganta tsarin. Nasarar hanyar gwajin hujja ta ta'allaka ne da yawa a hannun masu fasaha, don haka ana ba da shawarar ƙoƙarin haɗin gwiwa sosai.
Yawancin gwaje-gwajen tabbacin yawanci ana yin su ba tare da layi ba yayin rufewa ko juyawa. A wasu lokuta, ana iya buƙatar gwajin shaida don yin kan layi yayin gudana don gamsar da lissafin SIL ko wasu buƙatu. Gwajin kan layi yana buƙatar tsarawa da daidaitawa tare da Ayyuka don ba da damar yin gwajin shaida cikin aminci, ba tare da jin haushin tsari ba, kuma ba tare da haifar da balaguro ba. Yana ɗaukar tafiya mai ban tsoro ɗaya kawai don amfani da duk abokan aikin ku. A lokacin wannan nau'in gwajin, lokacin da SIF ba ta da cikakkiyar samuwa don yin aikinta na aminci, 61511-1, Sashe na 11.8.5, ya ce "Ma'auni na ramawa waɗanda ke tabbatar da ci gaba da aiki lafiya za a ba da su daidai da 11.3 lokacin da SIS ke cikin wucewa (gyara ko gwaji)." Ya kamata tsarin kula da yanayin rashin daidaituwa ya tafi tare da tsarin gwajin shaida don taimakawa tabbatar da yin hakan da kyau.
SIF yawanci ana raba shi zuwa manyan sassa uku: na'urori masu auna firikwensin, masu warware dabaru da abubuwa na ƙarshe. Har ila yau, akwai na'urori masu taimako da yawa waɗanda za a iya haɗa su a cikin kowane ɗayan waɗannan sassa uku (misali, shingen IS, amps na tafiya, relays, solenoids, da dai sauransu) waɗanda dole ne a gwada su. Za'a iya samun mahimman fa'idodi na gwajin shaida kowane ɗayan waɗannan fasahohin a cikin labarun gefe, "Na'urorin gwaji, masu warware dabaru da abubuwa na ƙarshe" (a ƙasa).
Wasu abubuwa sun fi sauran sauƙi don tantancewa. Yawancin zamani da ƴan tsofaffin kwarara da fasahohin matakin suna cikin mafi wahala kashi. Waɗannan sun haɗa da na'urori masu motsi na Coriolis, mita vortex, mita mag, radar ta iska, matakin ultrasonic, da na'urori masu sauyawa a cikin wurin, don suna kaɗan. Abin farin ciki, da yawa daga cikin waɗannan yanzu sun sami ingantaccen bincike wanda ke ba da damar ingantaccen gwaji.
Wahalar hujjar gwada irin wannan na'urar a cikin filin dole ne a yi la'akari da ƙirar SIF. Yana da sauƙi ga injiniyoyi don zaɓar na'urorin SIF ba tare da la'akari sosai da abin da za a buƙaci don gwada na'urar ba, tunda ba za su kasance mutanen da ke gwada su ba. Wannan kuma gaskiya ne game da gwajin juzu'i, wanda hanya ce ta gama gari don haɓaka matsakaicin yuwuwar gazawar SIF akan buƙatu (PFDavg), amma daga baya a kan ayyukan shuka ba ya son yin shi, kuma sau da yawa ba zai yiwu ba. Koyaushe samar da kulawar shuka na injiniyan SIFs dangane da gwajin hujja.
Gwajin shaida ya kamata ya haɗa da dubawa na shigarwa na SIF da gyara kamar yadda ake bukata don saduwa da 61511-1, Sashe na 16.3.2. Ya kamata a yi bincike na ƙarshe don tabbatar da cewa komai yana sama, da kuma duba sau biyu cewa an mayar da SIF da kyau a cikin sabis na tsari.
Rubuce-rubuce da aiwatar da kyakkyawan hanyar gwaji shine muhimmin mataki don tabbatar da amincin SIF a tsawon rayuwarsa. Ya kamata tsarin gwajin ya ba da cikakkun bayanai don tabbatar da cewa gwaje-gwajen da ake buƙata ana yin su akai-akai kuma cikin aminci da kuma rubuta su. Kasawa masu haɗari waɗanda ba a gwada su ta hanyar gwaje-gwajen shaida ya kamata a biya su don tabbatar da cewa an kiyaye amincin amincin SIF a tsawon rayuwarsa.
Rubuta kyakkyawar hanyar gwajin shaida na buƙatar hanya mai ma'ana don nazarin injiniya na yuwuwar gazawar haɗari, zaɓin hanyoyin, da rubuta matakan gwajin hujja waɗanda ke cikin ƙarfin gwajin shuka. A kan hanyar, sami siyan tsire-tsire a kowane matakai don gwaji, kuma horar da masu fasaha don yin da rubuta gwajin shaida tare da fahimtar mahimmancin gwajin. Rubuta umarni kamar kai ma'aikacin kayan aikin ne wanda zai yi aikin, kuma rayuwar ta dogara da samun gwajin daidai, saboda suna yi.
Testing sensors, logic solvers and final elements A SIF is typically divided up into three main parts, sensors, logic solvers and final elements. There also typically are auxiliary devices that can be associated within each of these three parts (e.g. I.S. barriers, trip amps, interposing relays, solenoids, etc.) that must also be tested.Sensor proof tests: The sensor proof test must ensure that the sensor can sense the process variable over its full range and transmit the proper signal to the SIS logic solver for evaluation. While not inclusive, some of the things to consider in creating the sensor portion of the proof test procedure are given in Table 1. Table 1: Sensor proof test considerations Process ports clean/process interface check, significant buildup noted Internal diagnostics check, run extended diagnostics if available Sensor calibration (5 point) with simulated process input to sensor, verified through to the DCS, drift check Trip point check High/High-High/Low/Low-Low alarms Redundancy, voting degradation Out of range, deviation, diagnostic alarms Bypass and alarms, restrike User diagnostics Transmitter Fail Safe configuration verified Test associated systems (e.g. purge, heat tracing, etc.) and auxiliary components Physical inspection Complete as-found and as-left documentation Logic solver proof test: When full-function proof testing is done, the logic solver’s part in accomplishing the SIF’s safety action and related actions (e.g. alarms, reset, bypasses, user diagnostics, redundancies, HMI, etc.) are tested. Partial or piecemeal function proof tests must accomplish all these tests as part of the individual overlapping proof tests. The logic solver manufacturer should have a recommended proof test procedure in the device safety manual. If not and as a minimum, the logic solver power should be cycled, and the logic solver diagnostic registers, status lights, power supply voltages, communication links and redundancy should be checked. These checks should be done prior to the full-function proof test.Don’t make the assumption that the software is good forever and the logic need not be tested after the initial proof test as undocumented, unauthorized and untested software and hardware changes and software updates can creep into systems over time and must be factored into your overall proof test philosophy. The management of change, maintenance, and revision logs should be reviewed to ensure they are up to date and properly maintained, and if capable, the application program should be compared to the latest backup.Care should also be taken to test all the user logic solver auxiliary and diagnostic functions (e.g. watchdogs, communication links, cybersecurity appliances, etc.).Final element proof test: Most final elements are valves, however, rotating equipment motor starters, variable-speed drives and other electrical components such as contactors and circuit breakers are also used as final elements and their failure modes must be analyzed and proof tested.The primary failure modes for valves are being stuck, response time too slow or too fast, and leakage, all of which are affected by the valve’s operating process interface at trip time. While testing the valve at operating conditions is the most desirable case, Operations would generally be opposed to tripping the SIF while the plant is operating. Most SIS valves are typically tested while the plant is down at zero differential pressure, which is the least demanding of operating conditions. The user should be aware of the worst-case operational differential pressure and the valve and process degradation effects, which should be factored into the valve and actuator design and sizing.Commonly, to compensate for not testing at process operating conditions, additional safety pressure/thrust/torque margin is added to the valve actuator and inferential performance testing is done utilizing baseline testing. Examples of these inferential tests are where the valve response time is timed, a smart positioner or digital valve controller is used to record a valve pressure/position curve or signature, or advance diagnostics are done during the proof test and compared with previous test results or baselines to detect valve performance degradation, indicating a potential incipient failure. Also, if tight shut off (TSO) is a requirement, simply stroking the valve will not test for leakage and a periodic valve leak test will have to be performed. ISA TR96.05.02 is intended to provide guidance on four different levels of testing of SIS valves and their typical proof test coverage, based on how the test is instrumented. People (particularly users) are encouraged to participate in the development of this technical report (contact crobinson@isa.org).Ambient temperatures can also affect valve friction loads, so that testing valves in warm weather will generally be the least demanding friction load when compared to cold weather operation. As a result, proof testing of valves at a consistent temperature should be considered to provide consistent data for inferential testing for the determination of valve performance degradation.Valves with smart positioners or a digital valve controller generally have capability to create a valve signature that can be used to monitor degradation in valve performance. A baseline valve signature can be requested as part of your purchase order or you can create one during the initial proof test to serve as a baseline. The valve signature should be done for both opening and closing of the valve. Advanced valve diagnostic should also be used if available. This can help tell you if your valve performance is deteriorating by comparing subsequent proof test valve signatures and diagnostics with your baseline. This type of test can help compensate for not testing the valve at worst case operating pressures.The valve signature during a proof test may also be able to record the response time with time stamps, removing the need for a stopwatch. Increased response time is a sign of valve deterioration and increased friction load to move the valve. While there are no standards regarding changes in valve response time, a negative pattern of changes from proof test to proof test is indicative of the potential loss of the valve’s safety margin and performance. Modern SIS valve proof testing should include a valve signature as a matter of good engineering practice.The valve instrument air supply pressure should be measured during a proof test. While the valve spring for a spring-return valve is what closes the valve, the force or torque involved is determined by how much the valve spring is compressed by the valve supply pressure (per Hooke’s Law, F = kX). If your supply pressure is low, the spring will not compress as much, hence less force will be available to move the valve when needed. While not inclusive, some of the things to consider in creating the valve portion of the proof test procedure are given in Table 2. Table 2: Final element valve assembly considerations Test valve safety action at process operating pressure (best but typically not done), and time the valve’s response time. Verify redundancy Test valve safety action at zero differential pressure and time valve’s response time. Verify redundancy Run valve signature and diagnostics as part of proof test and compare to baseline and previous test Visually observe valve action (proper action without unusual vibration or noise, etc.). Verify the valve field and position indication on the DCS Fully stroke the valve a minimum of five times during the proof test to help ensure valve reliability. (This is not intended to fix significant degradation effects or incipient failures). Review valve maintenance records to ensure any changes meet the required valve SRS specifications Test diagnostics for energize-to-trip systems Leak test if Tight Shut Off (TSO) is required Verify the command disagree alarm functionality Inspect valve assembly and internals Remove, test and rebuild as necessary Complete as-found and as-left documentation Solenoids Evaluate venting to provide required response time Evaluate solenoid performance by a digital valve controller or smart positioner Verify redundant solenoid performance (e.g. 1oo2, 2oo3) Interposing Relays Verify correct operation, redundancy Device inspection
Ana rarraba SIF zuwa manyan sassa uku, na'urori masu auna firikwensin, masu warware dabaru da abubuwa na ƙarshe. Har ila yau, yawanci akwai na'urori masu taimako waɗanda za a iya haɗa su a cikin kowane ɗayan waɗannan sassa uku (misali, shingen IS, amps na tafiya, relays na interposing, solenoids, da dai sauransu) waɗanda dole ne a gwada su.
Gwajin tabbatar da firikwensin: Gwajin hujjar firikwensin dole ne ya tabbatar da cewa firikwensin zai iya jin canjin tsari akan cikakken kewayon sa kuma ya watsa siginar da ta dace ga mai warware dabaru na SIS don kimantawa. Duk da yake ba a haɗa su ba, wasu abubuwan da za a yi la'akari da su wajen ƙirƙirar ɓangaren firikwensin tsarin gwajin hujja an bayar da su a cikin Tebu 1.
Gwajin hujja mai warware dabaru: Lokacin da aka yi cikakken gwajin hujja na aiki, ana gwada ɓangaren mai warware dabaru a cikin aiwatar da aikin aminci na SIF da ayyukan da ke da alaƙa (misali ƙararrawa, sake saiti, kewayawa, binciken mai amfani, sakewa, HMI, da sauransu). Gwajin aikin saɓani ko yanki dole ne ya cim ma duk waɗannan gwaje-gwajen a zaman wani ɓangare na gwaje-gwajen shaida mai ruɓani ɗaya. Ya kamata masana'anta masu warware dabaru su sami shawarar hanyar gwajin hujja a cikin littafin amintaccen na'urar. Idan ba haka ba kuma a mafi ƙanƙanta, ya kamata a yi amfani da wutar lantarki ta hanyar keke, kuma a bincika rajistar masu warware matsalar, fitilun matsayi, ƙarfin wutar lantarki, hanyoyin sadarwa da sakewa. Ya kamata a yi waɗannan cak ɗin kafin a fara gwajin tabbacin cikakken aiki.
Kada ku yi zaton cewa software ɗin tana da kyau har abada kuma ba za a gwada ma'anar ba bayan gwajin shaidar farko azaman software mara izini, mara izini kuma mara gwadawa da sauye-sauyen kayan masarufi da sabunta software na iya shiga cikin tsarin na tsawon lokaci kuma dole ne a ƙirƙira su cikin gabaɗayan ku. hujja gwajin falsafa. Gudanar da canje-canje, kiyayewa, da rajistan ayyukan bita ya kamata a sake duba su don tabbatar da cewa sun yi zamani kuma an kiyaye su yadda ya kamata, kuma idan ana iya, ya kamata a kwatanta shirin aikace-aikacen zuwa sabon madadin.
Hakanan ya kamata a kula don gwada duk mai warware dabaru na mai amfani da ayyukan bincike (misali masu sa ido, hanyoyin sadarwa, na'urorin tsaro na intanet, da sauransu).
Gwajin tabbatar da kashi na ƙarshe: Yawancin abubuwa na ƙarshe sune bawuloli, duk da haka, injina masu juyawa na kayan aiki, masu tafiyar da sauri da sauran abubuwan lantarki kamar masu tuntuɓar da keɓaɓɓiyar keɓancewa kuma ana amfani da su azaman abubuwa na ƙarshe kuma dole ne a bincika yanayin gazawar su kuma a gwada hujja.
Hanyoyin gazawar farko na bawuloli suna makale, lokacin mayar da martani ya yi jinkiri ko kuma da sauri, da yoyo, duk abin da tsarin aikin bawul ɗin ya shafa a lokacin tafiya. Yayin gwajin bawul a yanayin aiki shine mafi kyawun shari'ar, Ayyuka gabaɗaya za su yi adawa da ƙulla SIF yayin da shuka ke aiki. Yawancin bawuloli na SIS yawanci ana gwada su yayin da shuka ke ƙasa da matsa lamba na sifili, wanda shine mafi ƙarancin buƙatar yanayin aiki. Ya kamata mai amfani ya san mafi munin yanayin aiki na matsa lamba daban-daban da bawul da tasirin lalacewa, wanda ya kamata a sanya shi cikin bawul da ƙirar mai kunnawa da ƙima.
Commonly, to compensate for not testing at process operating conditions, additional safety pressure/thrust/torque margin is added to the valve actuator and inferential performance testing is done utilizing baseline testing. Examples of these inferential tests are where the valve response time is timed, a smart positioner or digital valve controller is used to record a valve pressure/position curve or signature, or advance diagnostics are done during the proof test and compared with previous test results or baselines to detect valve performance degradation, indicating a potential incipient failure. Also, if tight shut off (TSO) is a requirement, simply stroking the valve will not test for leakage and a periodic valve leak test will have to be performed. ISA TR96.05.02 is intended to provide guidance on four different levels of testing of SIS valves and their typical proof test coverage, based on how the test is instrumented. People (particularly users) are encouraged to participate in the development of this technical report (contact crobinson@isa.org).
Hakanan yanayin yanayin yanayi na iya rinjayar nauyin juzu'in bawul, ta yadda bawul ɗin gwaji a cikin yanayin zafi gabaɗaya za su kasance mafi ƙarancin nauyin juzu'i idan aka kwatanta da aikin yanayin sanyi. A sakamakon haka, ya kamata a yi la'akari da gwajin gwaji na bawuloli a daidaitaccen zafin jiki don samar da daidaitattun bayanai don gwaji na ƙima don ƙayyade lalacewar aikin valve.
Valves tare da masu sakawa masu wayo ko mai sarrafa bawul na dijital gabaɗaya suna da damar ƙirƙirar sa hannu na bawul wanda za'a iya amfani da shi don lura da lalacewa a cikin aikin bawul. Ana iya buƙatar sa hannu na bawul ɗin tushe azaman ɓangaren odar siyan ku ko kuna iya ƙirƙirar ɗaya yayin gwajin shaida na farko don zama tushen tushe. Ya kamata a yi sa hannu na bawul don buɗewa da rufewa na bawul. Hakanan ya kamata a yi amfani da na'urar bincike na bawul idan akwai. Wannan zai iya taimaka gaya muku idan aikin bawul ɗin ku yana lalacewa ta hanyar kwatanta sa hannun bawul ɗin gwaji na gaba da bincike tare da tushen ku. Irin wannan gwajin na iya taimakawa ramawa don rashin gwada bawul a mafi munin yanayin aiki.
Sa hannu na bawul yayin gwajin hujja na iya yin rikodin lokacin amsawa tare da tambarin lokaci, cire buƙatar agogon gudu. Ƙara lokacin amsawa alama ce ta lalacewar bawul da ƙãra kayan juzu'i don matsar da bawul. Duk da yake babu ƙa'idodi game da canje-canje a lokacin amsawar bawul, mummunan yanayin canje-canje daga gwajin shaida zuwa gwajin hujja yana nuni da yuwuwar asarar amintaccen gefen bawul da aikin. Gwajin tabbatar da bawul na SIS na zamani yakamata ya haɗa da sa hannu na bawul azaman al'amarin aikin injiniya mai kyau.
Ya kamata a auna matsa lamba na kayan aikin bawul ɗin iska yayin gwajin gwaji. Yayin da bawul ɗin bawul don bawul ɗin dawowar bazara shine abin da ke rufe bawul ɗin, ƙarfin ko jujjuyawar da ke tattare da shi ana ƙaddara ta nawa ne magudanar ruwan bawul ɗin ta matsa lamba ta hanyar bawul ɗin bawul (a cikin Dokar Hooke, F = kX). Idan matsi na samar da ku ya yi ƙasa, bazarar ba za ta damƙa da yawa ba, don haka ƙarancin ƙarfi zai kasance don motsa bawul ɗin lokacin da ake buƙata. Duk da yake ba a haɗa su ba, wasu abubuwan da za a yi la'akari da su wajen ƙirƙirar ɓangaren bawul na hanyar gwajin hujja an bayar da su a cikin Tebur 2.
Lokacin aikawa: Nuwamba 13-2019
