SIS Acceptance Testing Software Simulation vs. Hardware Simulation

2. SIS Acceptance TestingSoftware Simulation vs. Hardware Simulation Session Name: SimSci-Esscor Operation Part 2 Session ID #: PBSS213 Bret Moore 11/09/2011

3. PLC Acceptance Testing • The method for PLC Acceptance Testing has remained consistent since the advent of the PLC. This method included wiring input and output devices to termination panels to simulate process I/O and manually test all functions of the design specification. • However, with the availability of advanced emulation, the industry is seeing a trend that separates the logic testing from the hardware testing.

4. What is a Factory Acceptance Test? • Level 1 • Hardware and Electrical and Mechanical Inspection • Hardware Validation and Testing • No Simulation Hardware provided • No Logic Validation and Testing • Level II • Hardware and Electrical and Mechanical Inspection • Hardware Validation and Testing • Simulation Hardware provided • Logic Validation provided by the Customer

5. What is a Factory Acceptance Test? • Level III • Hardware and Electrical and Mechanical Inspection • Hardware Validation and Testing • Simulation Hardware provided • Customer Witnessed Logic Validation and Testing Using Customer Supplied Procedures or Functional Narrative. • Level IV • Hardware and Electrical and Mechanical Inspection • Hardware Validation and Testing • Simulation Hardware provided • Customer Witnessed Logic Validation and Testing Using Vendor Supplied Procedures or Functional Narrative.

6. What is a Purpose of a Factory Acceptance Test? The purpose of a Factory Acceptance is to achieve the following: Ensure the PLC Engineering Design, PLC Hardware, Enclosure and Fabrication meet the design specification of the application. Ensure the PLC Logic meets the design specification of the application. Question: If this is the purpose of a Factory Acceptance Test (FAT), can these two functions of the FAT be decoupled to achieve the same result? Answer: Yes, with the availability of advanced emulators, decoupling can result in significantly better results.

7. Variations to Acceptance Testing Hardware Simulation Provides a method to simulate Inputs (i.e.: Switches, Transmitters, TC Inputs) and verify correct output responses (i.e.: soft alarms/indications, hard outputs) via wired switches, current devices, TC inputs, etc.. Manual Simulation Engine Provides a method to simulate Inputs (i.e.: Switches, Transmitters, TC Inputs) and verify correct output responses (i.e.: soft alarms/indications, hard outputs) Automated Simulation Engine Provides the same method to simulate Inputs (i.e.: Switches, Transmitters, TC Inputs) and verify correct output responses (i.e.: soft alarms/indications, hard outputs). However, through the automated simulation, inputs are automatically adjusted and responses are automatically verified.

8. Hardware Simulation Benefits Allows the responsible party to have a better feel for testing because touching the simulation hardware and seeing the results on the monitor. Allows the responsible party to actually see the connections (wiring, communications, etc.) work. Drawbacks Costly – Simulation Hardware requires wiring of every configured point to I/O panels. In some cases, rental hardware is required for a fully functional FAT. Time Consuming – Flipping switches, turning pots and identifying appropriate responses on a simulation panel takes time. Not only is this time costly, but can lead to inaccuracies. Difficult to increase size of system to include multiple SIS, DCS for integrated testing.

9. Manual Simulation Engine Benefits Easy to increase size of system to include multiple SIS, DCS for integrated testing. Efficient - Allows the responsible party to respond quickly to the demands of the facilitator resulting in faster testing. Cost Effective – The initial purchase of simulation software can be costly, however when considering the hardware and labor costs involved in using Simulation Hardware, the cost of the Manual Simulation Engine could be significantly lower. No Program Upgrade required which guarantees the program being tested is the same as in the processor. Drawbacks Costly – Again, the initial purchase of simulation software can be costly. Depending on the number of installations, this method may not be justified. Time Consuming – Acceptance Testing using a Manual Simulation Engine is faster than Simulation Hardware but is still time consuming in higher cost and potential inaccuracy.

10. Automated Simulation Engine Benefits Accurate – No Fatigue Factor. The entire program can be tested in hours rather than days if changes occur. Easy to increase size of system to include multiple SIS, DCS for integrated testing Cost Effective – The initial purchase of simulation software can be costly, however when considering the hardware and labor costs involved in using Simulation Hardware, the cost of the Manual Simulation Engine could be significantly lower. Efficient – Extremely fast in comparison to manual testing even when stepping through the test line-line. Procedures written for an automated test can be used in an Automated Test Manual Simulated Test or Hardware Simulated Test. No Program Upgrade Required which guarantees the program being tested is the same as in the processor.

11. Automated Simulation Engine Drawbacks Costly – Again, the initial purchase of simulation software can be costly. Depending on the number of installations, this method may not be justified. Trust – It may take some time for the customer to consider this a viable method of testing simply because it doesn’t have the feel that the Manual Simulation (hardware or software) has.

12. Automated Testing Example – Trisim Plus Validator Software system to automate testing of SIS logic Tests logic solver part of the controls in a soft environment Excel-based interface to write validation scripts to test out logic Connects to PLC/DCS soft emulators via OPC UA, DA and Modbus protocols Soft emulators include Triconex, Allen-Bradley, Modicon, GE, Siemens, CCC, Woodward Foxboro, ABB, Emerson, Yokogawa, Honeywell etc Can connect to real hardware if necessary

13. Trisim Plus Validator Features Excel GUI controls simulation execution Add on new tests using Excel GUI Error checking of commands/tag names Ability to single-step the process One-click to run all tests Ability to specify test-subsets Ability to interrupt a run Ease of troubleshooting failed tests Enhanced documentation as per ISA-S84 Standards

14. Automated Test Example Derived from the FAT test procedure

15. Automated Test Summary Documentation

16. Automated Test Detailed Documentation and Troubleshooting

17. Sample for Multiple DCS/SIS Systems Proconex (Interface and Emulation for Experion) FSIM (Foxboro CP Emulation) Triconex Trisim Plus (4.x+) GE Mark VI Virtual Emulator Trisim Plus Validator Foxboro I/A Station For HMI Experion (ESVT) For HMI, Loading Controls

18. Questions?