Idanwo ẹri jẹ apakan pataki ti itọju iduroṣinṣin ailewu ti awọn ọna ṣiṣe ohun elo aabo wa (SIS) ati awọn eto ti o ni ibatan ailewu (fun apẹẹrẹ awọn itaniji pataki, ina & awọn ọna gaasi, awọn ọna titiipa ohun elo, ati bẹbẹ lọ). Idanwo ẹri jẹ idanwo igbakọọkan lati ṣe awari awọn ikuna ti o lewu, idanwo iṣẹ ṣiṣe ti o ni ibatan si ailewu (fun apẹẹrẹ atunto, awọn ipadabọ, awọn itaniji, awọn iwadii aisan, tiipa afọwọṣe, ati bẹbẹ lọ), ati rii daju pe eto naa pade ile-iṣẹ ati awọn iṣedede ita. Awọn abajade ti idanwo ẹri tun jẹ iwọn ti imunadoko ti eto iṣotitọ ẹrọ SIS ati igbẹkẹle aaye ti eto naa.
Awọn ilana idanwo ẹri bo awọn igbesẹ idanwo lati gbigba awọn igbanilaaye, ṣiṣe awọn iwifunni ati mu eto kuro ni iṣẹ fun idanwo lati rii daju idanwo pipe, ṣiṣe iwe idanwo ẹri ati awọn abajade rẹ, gbigbe eto naa pada si iṣẹ, ati iṣiro awọn abajade idanwo lọwọlọwọ ati ẹri iṣaaju igbeyewo esi.
ANSI/ISA/IEC 61511-1, Abala 16, ni wiwa idanwo ẹri SIS. Ijabọ imọ-ẹrọ ISA TR84.00.03 - “Iduroṣinṣin Imọ-ẹrọ ti Awọn Eto Instrumented Safety (SIS),” ni wiwa idanwo ẹri ati pe o wa labẹ atunyẹwo lọwọlọwọ pẹlu ẹya tuntun ti a nireti laipẹ. Ijabọ imọ-ẹrọ ISA TR96.05.02 - “Imudaniloju Imudaniloju inu-ipo ti Awọn falifu adaṣe” wa lọwọlọwọ idagbasoke.
Ijabọ UK HSE CRR 428/2002 - "Awọn ilana fun idanwo idaniloju ti awọn ọna ṣiṣe ohun elo aabo ni ile-iṣẹ kemikali" pese alaye lori idanwo ẹri ati ohun ti awọn ile-iṣẹ n ṣe ni UK.
Ilana idanwo ẹri da lori itupalẹ awọn ipo ikuna ti o lewu ti a mọ fun ọkọọkan awọn paati ninu iṣẹ irin-ajo aabo (SIF), iṣẹ ṣiṣe SIF gẹgẹbi eto, ati bii (ati bi) lati ṣe idanwo fun ikuna ti o lewu. mode. Idagbasoke ilana yẹ ki o bẹrẹ ni ipele apẹrẹ SIF pẹlu apẹrẹ eto, yiyan awọn paati, ati ipinnu akoko ati bii o ṣe le jẹri idanwo. Awọn ohun elo SIS ni awọn iwọn oriṣiriṣi ti iṣoro idanwo ẹri ti o gbọdọ gbero ni apẹrẹ SIF, iṣẹ ṣiṣe ati itọju. Fun apẹẹrẹ, awọn mita orifice ati awọn atagba titẹ jẹ rọrun lati ṣe idanwo ju Coriolis massflowmeters, awọn mita magi tabi awọn sensọ ipele radar nipasẹ-afẹfẹ. Ohun elo ati apẹrẹ àtọwọdá tun le ni ipa lori okeerẹ ti idanwo ẹri àtọwọdá lati rii daju pe eewu ati awọn ikuna incipient nitori ibajẹ, plugging tabi awọn ikuna ti o gbẹkẹle akoko ko ja si ikuna pataki laarin aarin idanwo ti a yan.
Lakoko ti awọn ilana idanwo ẹri jẹ idagbasoke ni igbagbogbo lakoko ipele imọ-ẹrọ SIF, wọn yẹ ki o tun ṣe atunyẹwo nipasẹ Aṣẹ Imọ-ẹrọ SIS aaye, Awọn iṣẹ ati awọn onimọ-ẹrọ ohun elo ti yoo ṣe idanwo naa. Ayẹwo ailewu iṣẹ (JSA) yẹ ki o tun ṣee ṣe. O ṣe pataki lati gba rira-in ọgbin lori kini awọn idanwo yoo ṣee ṣe ati nigbawo, ati iṣeeṣe ti ara ati ailewu wọn. Fun apẹẹrẹ, ko ṣe rere lati pato idanwo-ọpọlọ apakan nigbati ẹgbẹ Awọn iṣẹ ko ni gba lati ṣe. O tun ṣeduro pe awọn ilana idanwo ẹri jẹ atunyẹwo nipasẹ alamọja koko ọrọ ominira (SME). Idanwo aṣoju ti o nilo fun idanwo ẹri iṣẹ ni kikun jẹ alaworan ni Nọmba 1.
Awọn ibeere idanwo iṣẹ ni kikun Aworan 1: Apejuwe idanwo iṣẹ ni kikun fun iṣẹ ohun elo aabo (SIF) ati eto ohun elo aabo (SIS) yẹ ki o jade tabi tọka si awọn igbesẹ ni ọkọọkan lati awọn igbaradi idanwo ati awọn ilana idanwo si awọn iwifunni ati iwe .
Ṣe nọmba 1: Apejuwe idanwo idaniloju iṣẹ ni kikun fun iṣẹ ohun elo aabo (SIF) ati eto ohun elo aabo (SIS) yẹ ki o jade tabi tọka si awọn igbesẹ ni ọkọọkan lati awọn igbaradi idanwo ati awọn ilana idanwo si awọn iwifunni ati iwe.
Idanwo ẹri jẹ iṣẹ itọju ti a gbero ti o yẹ ki o ṣe nipasẹ oṣiṣẹ oṣiṣẹ ti o ni ikẹkọ ni idanwo SIS, ilana ẹri, ati awọn yipo SIS ti wọn yoo ṣe idanwo. Rin-nipasẹ ilana naa yẹ ki o wa ṣaaju ṣiṣe idanwo ẹri akọkọ, ati esi si aaye Imọ-ẹrọ SIS lẹhinna fun awọn ilọsiwaju tabi awọn atunṣe.
Awọn ọna ikuna akọkọ meji wa (ailewu tabi lewu), eyiti o pin si awọn ipo mẹrin-airotẹlẹ ti o lewu, ti a rii eewu (nipasẹ awọn iwadii aisan), ailewu ti ko rii ati ailewu rii. Awọn ofin ikuna ti o lewu ati ti o lewu ni a lo ni paarọ ninu nkan yii.
Ninu idanwo ẹri SIF, a nifẹ akọkọ ni awọn ipo ikuna ti a ko rii eewu, ṣugbọn ti awọn iwadii olumulo ba wa ti o rii awọn ikuna ti o lewu, awọn iwadii aisan wọnyi yẹ ki o jẹ idanwo ẹri. Ṣe akiyesi pe ko dabi awọn iwadii aisan olumulo, awọn iwadii inu ẹrọ ni igbagbogbo ko le ṣe ifọwọsi bi iṣẹ ṣiṣe nipasẹ olumulo, ati pe eyi le ni ipa lori imoye idanwo ẹri. Nigbati a ba gba kirẹditi fun awọn iwadii aisan ninu awọn iṣiro SIL, awọn itaniji iwadii (fun apẹẹrẹ awọn itaniji ti ita) yẹ ki o ṣe idanwo gẹgẹbi apakan ti idanwo ẹri.
Awọn ipo ikuna le pin siwaju si awọn ti idanwo fun lakoko idanwo ẹri, awọn ti ko ṣe idanwo fun, ati awọn ikuna ibẹrẹ tabi awọn ikuna ti o gbẹkẹle akoko. Diẹ ninu awọn ipo ikuna ti o lewu le ma ṣe idanwo taara fun awọn idi pupọ (fun apẹẹrẹ iṣoro, imọ-ẹrọ tabi ipinnu iṣẹ ṣiṣe, aimọkan, ailagbara, aisi tabi awọn aṣiṣe ilana igbimọ, iṣeeṣe kekere ti iṣẹlẹ, ati bẹbẹ lọ). Ti awọn ipo ikuna ti a mọ ti kii yoo ṣe idanwo fun, isanpada yẹ ki o ṣee ṣe ni apẹrẹ ẹrọ, ilana idanwo, rirọpo ẹrọ igbakọọkan tabi atunkọ, ati / tabi awọn idanwo inferential yẹ ki o ṣe lati dinku ipa lori iduroṣinṣin SIF ti kii ṣe idanwo.
Ikuna ibẹrẹ jẹ ipo irẹwẹsi tabi ipo bii pataki, ikuna ti o lewu le ṣee nireti lati waye ti ko ba ṣe awọn iṣe atunṣe ni akoko ti o to. Wọn jẹ wiwa ni igbagbogbo nipasẹ lafiwe iṣẹ ṣiṣe si aipẹ tabi awọn idanwo ẹri ala akọkọ (fun apẹẹrẹ awọn ibuwọlu àtọwọdá tabi awọn akoko idahun àtọwọdá) tabi nipasẹ ayewo (fun apẹẹrẹ ibudo ilana edidi). Awọn ikuna ibẹrẹ jẹ igbẹkẹle igbagbogbo-akoko ti ẹrọ tabi apejọ ba wa ni iṣẹ, diẹ sii ni ibajẹ ti o di; awọn ipo ti o dẹrọ a ID ikuna di diẹ seese, ilana ibudo plugging tabi sensọ buildup lori akoko, awọn wulo aye ti pari, bbl Nitorina, awọn gun awọn ẹri aarin aarin, awọn diẹ seese ohun incipient tabi akoko-ti o gbẹkẹle ikuna. Eyikeyi awọn aabo lodi si awọn ikuna ibẹrẹ tun gbọdọ jẹ idanwo ẹri (mimọ ibudo, wiwa kakiri ooru, ati bẹbẹ lọ).
Awọn ilana gbọdọ wa ni kikọ si idanwo ẹri fun awọn ikuna ti o lewu (ti a ko rii). Ipo ikuna ati itupalẹ ipa (FMEA) tabi ipo ikuna, ipa ati itupalẹ iwadii (FMEDA) le ṣe iranlọwọ idanimọ awọn ikuna ti a ko rii ti o lewu, ati nibiti agbegbe idanwo ẹri gbọdọ ni ilọsiwaju.
Ọpọlọpọ awọn ilana idanwo ẹri ni a kọ iriri orisun ati awọn awoṣe lati awọn ilana ti o wa tẹlẹ. Awọn ilana titun ati awọn SIFs idiju diẹ sii pe fun ọna ti o ni imọran diẹ sii nipa lilo FMEA / FMDA lati ṣe itupalẹ fun awọn ikuna ti o lewu, pinnu bi ilana idanwo naa yoo ṣe tabi kii yoo ṣe idanwo fun awọn ikuna naa, ati iṣeduro awọn idanwo naa. Aworan idinamọ ipo ikuna ipele macro fun sensọ kan han ni Nọmba 2. FMEA nigbagbogbo nilo lati ṣee ṣe lẹẹkan fun iru ẹrọ kan ati tun lo fun awọn ẹrọ ti o jọra pẹlu akiyesi iṣẹ ilana wọn, fifi sori ẹrọ ati awọn agbara idanwo aaye .
Onínọmbà ikuna ipele Makiro Nọmba 2: Aworan atọka ipinnu ipo ikuna ipele macro yii fun sensọ ati atagba titẹ (PT) fihan awọn iṣẹ pataki ti yoo jẹ igbagbogbo fọ si isalẹ awọn itupalẹ ikuna micro pupọ lati ṣalaye ni kikun awọn ikuna ti o pọju lati koju ninu awọn idanwo iṣẹ.
Ṣe nọmba 2: Aworan atọka atọka ipo ikuna ipele macro yii fun sensọ ati atagba titẹ (PT) ṣe afihan awọn iṣẹ pataki ti yoo jẹ igbagbogbo fọ si isalẹ awọn itupalẹ ikuna bulọọgi pupọ lati ṣalaye ni kikun awọn ikuna ti o pọju lati koju ninu awọn idanwo iṣẹ.
Iwọn ogorun ti a mọ, lewu, awọn ikuna ti a ko rii ti o jẹ idanwo ẹri ni a pe ni agbegbe idanwo ẹri (PTC). PTC jẹ lilo nigbagbogbo ni awọn iṣiro SIL lati “sansan” fun ikuna lati ṣe idanwo SIF ni kikun diẹ sii. Awọn eniyan ni igbagbọ aṣiṣe pe nitori pe wọn ti ṣe akiyesi aini agbegbe idanwo ni iṣiro SIL wọn, wọn ti ṣe apẹrẹ SIF ti o gbẹkẹle. Otitọ ti o rọrun ni, ti agbegbe idanwo rẹ ba jẹ 75%, ati pe ti o ba ṣe ifọkansi nọmba yẹn sinu iṣiro SIL rẹ ati idanwo awọn nkan ti o ti n ṣe idanwo ni igbagbogbo, 25% ti awọn ikuna ti o lewu le tun waye ni iṣiro. Mo dajudaju ko fẹ lati wa ninu 25%.
Awọn ijabọ ifọwọsi FMDA ati awọn iwe afọwọkọ aabo fun awọn ẹrọ ni igbagbogbo pese ilana idanwo ẹri ti o kere ju ati agbegbe idanwo ẹri. Iwọnyi pese itọsọna nikan, kii ṣe gbogbo awọn igbesẹ idanwo ti o nilo fun ilana idanwo ẹri okeerẹ. Awọn oriṣi miiran ti itupalẹ ikuna, gẹgẹbi itupalẹ igi ẹbi ati itọju aarin igbẹkẹle, ni a tun lo lati ṣe itupalẹ fun awọn ikuna ti o lewu.
Awọn idanwo idaniloju le pin si iṣẹ-ṣiṣe ni kikun (ipari-si-opin) tabi idanwo iṣẹ-apakan (Aworan 3). Idanwo iṣẹ-apakan ni a ṣe nigbagbogbo nigbati awọn paati SIF ni awọn aaye arin idanwo oriṣiriṣi ninu awọn iṣiro SIL ti ko ṣe laini pẹlu awọn titiipa ti a gbero tabi awọn iyipo. O ṣe pataki pe awọn ilana idanwo ẹri iṣẹ-apakan ni lqkan iru pe papọ wọn ṣe idanwo gbogbo iṣẹ ṣiṣe aabo ti SIF. Pẹlu idanwo iṣẹ-apakan, o tun ṣeduro pe SIF ni idanwo ẹri ibẹrẹ-si-opin, ati awọn ti o tẹle lakoko awọn iyipada.
Awọn idanwo ẹri apakan yẹ ki o ṣafikun Nọmba 3: Awọn idanwo idaniloju apakan apapọ (isalẹ) yẹ ki o bo gbogbo awọn iṣẹ ṣiṣe ti idanwo ẹri iṣẹ ni kikun (oke).
Nọmba 3: Awọn idanwo idaniloju apakan ti o ni idapo (isalẹ) yẹ ki o bo gbogbo awọn iṣẹ ṣiṣe ti idanwo iṣẹ-ṣiṣe kikun (oke).
Idanwo ẹri apa kan ṣe idanwo ida kan ti awọn ipo ikuna ẹrọ kan. Apeere ti o wọpọ jẹ idanwo àtọwọdá apa kan, nibiti a ti gbe àtọwọdá naa ni iye kekere (10-20%) lati rii daju pe ko di. Eyi ni agbegbe idanwo ẹri kekere ju idanwo ẹri lọ ni aarin idanwo akọkọ.
Awọn ilana idanwo ẹri le yatọ ni idiju pẹlu idiju ti SIF ati imoye ilana idanwo ile-iṣẹ. Diẹ ninu awọn ile-iṣẹ kọ awọn ilana idanwo igbese-nipasẹ-igbesẹ alaye, lakoko ti awọn miiran ni awọn ilana kukuru kukuru. Awọn itọkasi si awọn ilana miiran, gẹgẹbi isọdiwọn boṣewa, ni a lo nigbakan lati dinku iwọn ilana idanwo ẹri ati lati ṣe iranlọwọ rii daju pe aitasera ninu idanwo. Ilana idanwo ẹri ti o dara yẹ ki o pese alaye ti o to lati rii daju pe gbogbo idanwo naa ti ṣaṣeyọri daradara ati ti ni akọsilẹ, ṣugbọn kii ṣe alaye pupọ lati fa ki awọn onimọ-ẹrọ fẹ lati fo awọn igbesẹ. Nini onimọ-ẹrọ, ẹniti o ni iduro fun ṣiṣe igbesẹ idanwo, ni ibẹrẹ igbesẹ idanwo ti o pari le ṣe iranlọwọ rii daju pe idanwo naa yoo ṣee ṣe deede. Iforukọsilẹ ti idanwo ẹri ti o pari nipasẹ Alabojuto Irinṣẹ ati awọn aṣoju Awọn iṣẹ yoo tun tẹnumọ pataki ati ṣe idaniloju idanwo ẹri ti o pari daradara.
Awọn esi onimọ-ẹrọ yẹ ki o pe nigbagbogbo lati ṣe iranlọwọ lati mu ilana naa dara sii. Aṣeyọri ti ilana idanwo ẹri wa ni apakan nla ni awọn ọwọ onimọ-ẹrọ, nitorinaa igbiyanju ifowosowopo jẹ iṣeduro gaan.
Pupọ idanwo ẹri jẹ igbagbogbo ṣe ni ita laini lakoko tiipa tabi yiyi pada. Ni awọn igba miiran, idanwo ẹri le nilo lati ṣe lori ayelujara lakoko ṣiṣe lati ni itẹlọrun awọn iṣiro SIL tabi awọn ibeere miiran. Idanwo ori ayelujara nilo igbero ati isọdọkan pẹlu Awọn iṣẹ ṣiṣe lati gba idanwo ẹri laaye lati ṣee ṣe lailewu, laisi ilana bibanujẹ, ati laisi fa irin-ajo apanirun kan. Yoo gba irin-ajo alarinrin kan ṣoṣo lati lo gbogbo awọn attaboys rẹ. Lakoko iru idanwo yii, nigbati SIF ko ba wa ni kikun lati ṣe iṣẹ-ṣiṣe aabo rẹ, 61511-1, Abala 11.8.5, sọ pe “Awọn igbese isanpada ti o rii daju pe iṣẹ ailewu tẹsiwaju yoo pese ni ibamu pẹlu 11.3 nigbati SIS wa ninu fori (atunṣe tabi idanwo)." Ilana iṣakoso ipo ajeji yẹ ki o lọ pẹlu ilana idanwo ẹri lati ṣe iranlọwọ rii daju pe eyi ṣe daradara.
A SIF ni igbagbogbo pin si awọn ẹya akọkọ mẹta: awọn sensosi, awọn olutayo ọgbọn ati awọn eroja ikẹhin. Awọn ẹrọ oluranlọwọ nigbagbogbo wa ti o le ni nkan ṣe laarin ọkọọkan awọn ẹya mẹta wọnyi (fun apẹẹrẹ awọn idena IS, amps irin-ajo, awọn relays interposing, solenoids, ati bẹbẹ lọ) ti o tun gbọdọ ni idanwo. Awọn aaye to ṣe pataki ti idanwo ẹri kọọkan ninu awọn imọ-ẹrọ wọnyi le rii ni ẹgbẹ ẹgbẹ, “Awọn sensọ idanwo, awọn oluyanju ọgbọn ati awọn eroja ikẹhin” (isalẹ).
Diẹ ninu awọn ohun rọrun lati jẹri idanwo ju awọn miiran lọ. Pupọ igbalode ati ṣiṣan agbalagba diẹ ati awọn imọ-ẹrọ ipele wa ni ẹka ti o nira diẹ sii. Iwọnyi pẹlu awọn olutọpa ṣiṣan Coriolis, awọn mita vortex, awọn mita magi, radar nipasẹ-air, ipele ultrasonic, ati awọn iyipada ilana inu-ile, lati lorukọ diẹ. O da, ọpọlọpọ ninu iwọnyi ni awọn iwadii imudara ti o gba laaye idanwo ilọsiwaju.
Iṣoro ti idanwo ẹri iru ẹrọ kan ni aaye gbọdọ jẹ akiyesi ni apẹrẹ SIF. O rọrun fun imọ-ẹrọ lati yan awọn ẹrọ SIF laisi ero pataki ti ohun ti yoo nilo lati ṣe idanwo ẹrọ naa, nitori wọn kii yoo jẹ eniyan ti n danwo wọn. Eyi tun jẹ otitọ ti idanwo-ọpọlọ apakan, eyiti o jẹ ọna ti o wọpọ lati mu ilọsiwaju iṣeeṣe apapọ SIF kan ti ikuna lori ibeere (PFDavg), ṣugbọn nigbamii lori Awọn iṣẹ ọgbin ko fẹ ṣe, ati pe ọpọlọpọ igba le ma ṣe. Nigbagbogbo pese abojuto ọgbin ti imọ-ẹrọ ti SIFs ni n ṣakiyesi si idanwo ẹri.
Idanwo ẹri yẹ ki o pẹlu ayewo ti fifi sori SIF ati atunṣe bi o ṣe nilo lati pade 61511-1, Abala 16.3.2. Ayewo ikẹhin yẹ ki o wa lati rii daju pe ohun gbogbo wa ni bọtini, ati ṣayẹwo ilọpo meji pe SIF ti gbe pada daradara sinu iṣẹ ilana.
Kikọ ati imuse ilana idanwo to dara jẹ igbesẹ pataki lati rii daju pe iduroṣinṣin ti SIF lori igbesi aye rẹ. Ilana idanwo yẹ ki o pese awọn alaye ti o to lati rii daju pe awọn idanwo ti o nilo ni a ṣe ni igbagbogbo ati ni aabo ati ṣe akọsilẹ. Awọn ikuna ti o lewu ti a ko ṣe idanwo nipasẹ awọn idanwo ẹri yẹ ki o sanpada fun lati rii daju pe iduroṣinṣin ailewu SIF ti ni itọju daradara ni igbesi aye rẹ.
Kikọ ilana idanwo ẹri to dara nilo ọna ọgbọn si itupalẹ imọ-ẹrọ ti awọn ikuna ti o lewu ti o pọju, yiyan awọn ọna, ati kikọ awọn igbesẹ idanwo ẹri ti o wa laarin awọn agbara idanwo ọgbin. Ni ọna, gba rira ohun ọgbin ni gbogbo awọn ipele fun idanwo naa, ki o kọ awọn onimọ-ẹrọ lati ṣe ati ṣe igbasilẹ idanwo ẹri bii oye pataki idanwo naa. Kọ awọn itọnisọna bi ẹnipe o jẹ onimọ-ẹrọ ohun elo ti yoo ni lati ṣe iṣẹ naa, ati pe awọn igbesi aye da lori gbigba idanwo ni ẹtọ, nitori wọn ṣe.
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
A SIF ni igbagbogbo pin si awọn ẹya akọkọ mẹta, awọn sensọ, awọn olutayo ọgbọn ati awọn eroja ikẹhin. Awọn ẹrọ oniranlọwọ tun wa ti o le ni nkan ṣe laarin ọkọọkan awọn ẹya mẹta wọnyi (fun apẹẹrẹ awọn idena IS, awọn amps irin-ajo, relays interposing, solenoids, ati bẹbẹ lọ) ti o tun gbọdọ ni idanwo.
Awọn idanwo imudaniloju sensọ: Idanwo ẹri sensọ gbọdọ rii daju pe sensọ le ni oye iyipada ilana lori iwọn kikun rẹ ati gbe ifihan agbara to dara si oluyanju ọgbọn SIS fun igbelewọn. Lakoko ti kii ṣe ifisi, diẹ ninu awọn nkan lati ronu ni ṣiṣẹda ipin sensọ ti ilana idanwo ẹri ni a fun ni Tabili 1.
Idanwo ẹri oluyanju kannaa: Nigbati idanwo ẹri iṣẹ-kikun ba ti ṣe, apakan oluyanju ọgbọn ni ṣiṣe aṣeyọri iṣẹ aabo SIF ati awọn iṣe ti o jọmọ (fun apẹẹrẹ awọn itaniji, atunto, awọn ọna abayọ, awọn iwadii olumulo, awọn apadabọ, HMI, ati bẹbẹ lọ) ni idanwo. Awọn idanwo ẹri iṣẹ apakan tabi apakan gbọdọ ṣaṣeyọri gbogbo awọn idanwo wọnyi gẹgẹbi apakan ti awọn idanwo ẹri agbekọja kọọkan. Olupese oluṣeto ọgbọn yẹ ki o ni ilana idanwo ẹri ti a ṣeduro ninu afọwọṣe aabo ẹrọ. Ti kii ba ṣe bẹ ati bi o kere ju, agbara olutayo oye yẹ ki o wa ni gigun kẹkẹ, ati awọn iforukọsilẹ idanimọ oye, awọn ina ipo, awọn foliteji ipese agbara, awọn ọna asopọ ibaraẹnisọrọ ati apọju yẹ ki o ṣayẹwo. Awọn sọwedowo wọnyi yẹ ki o ṣee ṣe ṣaaju idanwo ẹri iṣẹ ni kikun.
Maṣe ṣe arosinu pe sọfitiwia naa dara lailai ati pe oye ko nilo lati ni idanwo lẹhin idanwo ẹri akọkọ bi laini iwe-aṣẹ, sọfitiwia laigba aṣẹ ati ti ko ni idanwo ati awọn ayipada ohun elo ati awọn imudojuiwọn sọfitiwia le wọ inu awọn eto ni akoko pupọ ati pe o gbọdọ jẹ ifosiwewe sinu gbogbogbo rẹ. imoye igbeyewo ẹri. Isakoso ti iyipada, itọju, ati awọn iwe atunwo yẹ ki o ṣe atunyẹwo lati rii daju pe wọn wa titi di oni ati ṣetọju daradara, ati pe ti o ba lagbara, eto ohun elo yẹ ki o ṣe afiwe si afẹyinti tuntun.
Itọju yẹ ki o tun ṣe lati ṣe idanwo gbogbo oluranlọwọ onitumọ oye olumulo ati awọn iṣẹ iwadii (fun apẹẹrẹ awọn oluṣọ, awọn ọna asopọ ibaraẹnisọrọ, awọn ohun elo cybersecurity, ati bẹbẹ lọ).
Idanwo ẹri ohun elo ikẹhin: Pupọ awọn eroja ikẹhin jẹ awọn falifu, sibẹsibẹ, awọn olupilẹṣẹ ẹrọ ẹrọ iyipo, awọn awakọ iyara-ayipada ati awọn paati itanna miiran gẹgẹbi awọn olutọpa ati awọn fifọ Circuit tun lo bi awọn eroja ikẹhin ati awọn ipo ikuna wọn gbọdọ ṣe itupalẹ ati idanwo ẹri.
Awọn ipo ikuna akọkọ fun awọn falifu ti wa ni di, akoko idahun o lọra tabi yiyara ju, ati jijo, gbogbo eyiti o ni ipa nipasẹ wiwo ilana iṣẹ ti àtọwọdá ni akoko irin ajo. Lakoko ti o ṣe idanwo àtọwọdá ni awọn ipo iṣẹ jẹ ọran ti o nifẹ julọ, Awọn iṣiṣẹ yoo ni gbogbogbo ni ilodisi si tripping SIF lakoko ti ohun ọgbin n ṣiṣẹ. Pupọ awọn falifu SIS ni a ṣe idanwo ni igbagbogbo lakoko ti ohun ọgbin wa ni isalẹ ni titẹ iyatọ odo, eyiti o jẹ ibeere ti o kere julọ ti awọn ipo iṣẹ. Olumulo yẹ ki o mọ ti titẹ iyatọ iṣẹ ṣiṣe ti o buru julọ ati àtọwọdá ati awọn ipa ibajẹ ilana, eyi ti o yẹ ki o jẹ ifosiwewe sinu àtọwọdá ati apẹrẹ actuator ati iwọn.
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).
Awọn iwọn otutu ibaramu tun le ni ipa lori awọn ẹru ikọlu falifu, nitorinaa awọn falifu idanwo ni oju ojo gbona yoo jẹ ẹru ija ija ti o kere julọ nigbati akawe si iṣẹ oju ojo tutu. Bi abajade, idanwo ẹri ti awọn falifu ni iwọn otutu deede yẹ ki o gbero lati pese data deede fun idanwo inferential fun ipinnu ibajẹ iṣẹ ṣiṣe valve.
Awọn falifu pẹlu awọn ipo ọlọgbọn tabi oluṣakoso àtọwọdá oni nọmba ni gbogbogbo ni agbara lati ṣẹda ibuwọlu àtọwọdá ti o le ṣee lo lati ṣe atẹle ibajẹ ni iṣẹ àtọwọdá. Ibuwọlu àtọwọdá ipilẹ kan le beere gẹgẹbi apakan ti aṣẹ rira rẹ tabi o le ṣẹda ọkan lakoko idanwo ẹri akọkọ lati ṣiṣẹ bi ipilẹ. Ibuwọlu àtọwọdá yẹ ki o ṣee ṣe fun ṣiṣi mejeeji ati pipade ti àtọwọdá naa. Ayẹwo àtọwọdá ti ilọsiwaju yẹ ki o tun ṣee lo ti o ba wa. Eyi le ṣe iranlọwọ lati sọ fun ọ boya iṣẹ ṣiṣe àtọwọdá rẹ n bajẹ nipa fifiwera awọn ibuwọlu àtọwọdá idanwo ẹri ti o tẹle ati awọn iwadii aisan pẹlu ipilẹṣẹ rẹ. Iru idanwo yii le ṣe iranlọwọ isanpada fun ko ṣe idanwo àtọwọdá ni awọn igara iṣẹ ṣiṣe ti o buruju.
Ibuwọlu falifu lakoko idanwo ẹri le tun ni anfani lati ṣe igbasilẹ akoko idahun pẹlu awọn ontẹ akoko, yiyọ iwulo fun aago iṣẹju-aaya kan. Akoko idahun ti o pọ si jẹ ami ti ibajẹ àtọwọdá ati ẹru edekoyede pọ si lati gbe àtọwọdá naa. Lakoko ti ko si awọn iṣedede nipa awọn ayipada ni akoko idahun àtọwọdá, apẹẹrẹ odi ti awọn ayipada lati idanwo ẹri si idanwo ẹri jẹ itọkasi ti ipadanu agbara ti ala ailewu ati iṣẹ ṣiṣe. Idanwo ẹri àtọwọdá SIS ode oni yẹ ki o pẹlu ibuwọlu àtọwọdá bi ọrọ ti iṣe ṣiṣe ẹrọ to dara.
Agbara ipese afẹfẹ ti ohun elo àtọwọdá yẹ ki o wọnwọn lakoko idanwo ẹri. Lakoko ti orisun omi àtọwọdá fun àtọwọdá ipadabọ orisun omi jẹ ohun ti o tilekun àtọwọdá, agbara tabi iyipo ti o wa ni ipinnu nipasẹ iye orisun omi àtọwọdá ti a fisinuirindigbindigbin nipasẹ titẹ ipese valve (fun Ofin Hooke, F = kX). Ti titẹ ipese rẹ ba lọ silẹ, orisun omi kii yoo rọpọ pupọ, nitorinaa agbara diẹ yoo wa lati gbe àtọwọdá nigbati o nilo. Lakoko ti kii ṣe ifisi, diẹ ninu awọn nkan lati gbero ni ṣiṣẹda apakan àtọwọdá ti ilana idanwo ẹri ni a fun ni Tabili 2.
Akoko ifiweranṣẹ: Oṣu kọkanla-13-2019
