The Virtual Process The Virtual Process Overview and ApplicationsOverview and Applications

Cape Software Inc.

Overview and ApplicationsOverview and Applications

Cape Software Inc.Houston TX

What is VP Link ?What is VP Link ?

A dynamic representation of a chemical y pprocess to an offline control system.

TheThe VVirtualirtual PProcess Looprocess LoopThe The VVirtual irtual PProcess Looprocess LoopRead Control OutputsCalculate new process states via configured

algorithmsWrite new process variablesWrite new process variables

Read value of outputs VP Link

CalculateP

Controllers(real / simulated)

Server

Write simulated inputs

ProcessVariables

(real / simulated)

p

Supported SystemsSupported SystemsSupported SystemsSupported Systems

Honeywell Experion PKS ,TPS , Honeywell FSC, y p , , y ,eXperion Safety ManagerHoneywell Plantscape / Rockwell ProcessLogixF b I/A i A h t A2Foxboro I/A series, Archestra, A2

Triconex:Tricon / Trident / EmulatorGE Fanuc series 90GE Fanuc series 90A-B PLC5/SLC500,CLX, Modicon,Siemens-Ti 505Siemens APACS, PCS7, S7, ,ABB Mod300, AdvantYokogawa CS3000/R3/ ProSafeEtc...

Some of our customers...Some of our customers...

5 steps to Logic Validation5 steps to Logic Validation5 steps to Logic Validation 5 steps to Logic Validation with VP Link 3.x with VP Link 3.x

1. Extract the control system I/O image, using fully automated , platform specific tools

2 Import the image in VP Link2. Import the image in VP Link3. Write training/failure scenarios and process tiebacks4. Connect to FSC (simulation box or plant CPU during4. Connect to FSC (simulation box or plant CPU during

turnaround)5. Execute validation test (scenario based or manually)

VP Link /VP Link / FSCFSCVP Link / VP Link / FSCFSCInterface Interface SpecificsSpecifics

Automated Extraction utility for up to date I/O databaseAutomated Extraction utility for up to date I/O database image for running periodical testsFast RS485 interface ,allowing total turnaround time lower than 800ms(depending on system load)lower than 800ms(depending on system load)Writes to Real Inputs or com points locations for exhaustive testing ( DCS resets etc…) via development

l( N i )protocol(same as Navigator)

Validate the non-modified version of your ControlValidate the non modified version of your Control Program :

What you test is what you deliver to the field!

FSC FSC Interface OverviewInterface Overview

VP Link Workstation

FSC Navigator StationFSC Navigator Station

Simultaneous Serial Communication On additional COM port

Hardware Interface Hardware Interface :FSC :FSC OverviewOverview

VP Link Workstation VP Link I/O Modules

Ethernet

nput

sW

rite

In

Out

puts

Requires real FSC chassis with FTA

FSC Navigator StationHard Wires to FTA R

ead

OFTA

Serial Communication

FSC I fFSC I f D ilD ilFSC Interface FSC Interface DetailsDetails

Automated Extraction for easy setup and match with terminator I/O modules, based on Honeywell h dhardware arrangementDirect stimulation of Honeywell field terminator assembly (FTA)assembly (FTA)No change/modification to the application

FSC Software suite can also include drivers for:FSC via development protocol RS232/485 O Eth t b d f S f t MOr Ethernet based for Safety ManagerWhy ? timer/soft points R/W

HSF : Setup for Staging floorHSF : Setup for Staging floorTerminator IO

Si lSignal conditioning boards

VP Link k t ti

DETAILworkstation

Power supplyEthernet ModuleTerminator IOs Signal conditioning

Boards for AIs, RTDs etc

VP Link ApplicationsVP Link Applications

Logic Validation

Cost of changes over a typical Cost of changes over a typical project development cycle project development cycle

Incre Minimal to Maximal ementa

moderateimpact

cost impact

al Cost

Time IAT FAT SAT PSSR

VV--Approach methodology:Approach methodology:li ti t lid tili ti t lid tiapplication to validationapplication to validation

Safety R i t

Pre Start-Up S f tRequirement

Spec

Run manual

Safety Review

Narrative

C & D l

Run manualTests

Cause &Effect

Function

DevelopScenarios

Function Block

Design

Black BoxTesting

DeliverableFunctional

Logic

Deliverable

Verification

Logic Validation with VP LinkLogic Validation with VP LinkVP Link Allows:

Graphics verificationpLogic checkout at I/O / block / module / system levelInterlock schedule approval Integrated Testing :Mapping to DCS and interactionIntegrated Testing :Mapping to DCS and interaction between DCS/PLC logic ( gateway points tests)

How ?Automates repetitive testing task (ie resets etc…)Facilitates FAT with customized graphics Collaborative testing framework thru distributed garchitecture

Thoroughly debug prior to online download, ie, Management of Change and periodical testingManagement of Change and periodical testingTest Compiler complies with IEC61508/61511

Simulation Screen shotsSimulation Screen shotsSimulation Screen shotsSimulation Screen shotsAutomated Tag sheet f l ifor manual testing

AutomatedInp t / O tp t sheets per ESDInput / Output sheets per ESD

HMI for advanced testingHMI for advanced testing or training

VP Link ApplicationsVP Link Applications

Automated Logic Validation

OSHA 29 CFR P t 1910OSHA 29 CFR Part 1910Emergency Shutdown systems :Document each inspection and test, including:

-Date of testN f h f d th t t [ ]

IEC-61511-116 3 1 1: Periodic proof test shall be

-Name of person who performed the test [..]-Description of test results

16.3.1.1: Periodic proof test shall be conducted using a written procedure to reveal undetected faultsOur Answer ?

Test CompilerIEC-61508Part 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.P 1 7 14 D i f lid i h ll i l dPart 1,7.14 :Documentation for validation shall include:

-Activities in chronological order-Discrepancies between expected and actual results

VP Li kVP Li k TT tt CC ililVP Link VP Link TTest est CCompilerompiler

Generates Test Scripts, using an Excel front-endS i t B d C t T t Pl d F ti lScripts Based on Customer Test Plan and Functional SpecificationsA Script is a stand alone entity that:p y

Forces inputs to a specified StateCompares the outputs to an expected state table ( Cause and Effect Matrix)and Effect Matrix)Logs discrepancies to HTML format

Runs and documents entire test plan unattendedResults Summarizer utilityScenario Template Generator

TC Master DocumentTC Master DocumentTC Master DocumentTC Master Document• Similar to a Cause and Effect Matrix• Copy and paste from original C&E• Copy and paste from original C&E• Verify ALL outputs change• Scripting keywords for maximum flexibility

Tests execution setup: Tests execution setup: ppOption for Integrated Option for Integrated Testing of Distributed Program Testing of Distributed Program

DCS (O ti l) SIS MMI:DCS (Optional) SIS MMI:

FSC Navigator

VP Link ForceForce

Validate

FSC or Safety Manager Chassis

Test Compiler output (1): Test Compiler output (1): HTML Test DescriptionHTML Test Description

Source

D:\tb40\Books\Refinery\BMS.xls[templates]Documentation created: Jun 19, 2003 at 13:08Source File: D:\tb40\Books\refinery[template] last modified Jun 19, 2003 at 13:03Purpose:

History

DatabaseThis scenario will: Start Heater Purge and Verify Purge CompletionVP Database:This scenario is designed to run with the database in refinery_5.cfg. Click on these links for the list of input and outputtags. 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

Global Parameters e s d d de y se ed be o e v ues e c ec ed s seco ds o s sce o. e e ve o e ce used e es

for equality is 0.002 %. Values in SET_HI and SET_LO commands are set 1 units above or below the alarm value specified in the Excel sheet.Scenario Actions:…… Turn i17HS0669B OFF, Field Trip for Heater

Parameters

ScenarioLine 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 10Line 8(Row 10): Set i17LT1641 to 10

Scenario Steps

Line 8(Row 10): Set i17LT1641 to 10.

ETC….

Test Compiler output (2): Test Compiler output (2): Test Test Outcome LogsOutcome Logs

Log SampleLog Sample0 Starting test 'D:\TB40\BOOKS\FLINT\PLC5\H1_BRNR.SCE'

at Wed May 28 18:23:48 20031181 # …1181 # …1181 # … 17H-1 Start Main Burner Sequence1181 # … Satisfy and Reset Fuel Gas Trip1181 # … Turn i17HS1964, i17HS1964A ON to Satisfy FG Trip5397 # … Turn i17HS1964RST ON to Reset FG Trip9614 # … Turn i17HS1923 ON to Start Main Burner

Time stamps

13830 # Test at line 10 of 'H1_BRNR.SCE' ON i17HS192313830 Verification <i17XY1904> = 1.000000 passed13830 **Verification <i17XY2419> = 1.000000 FAILED Value is 0.00000013830 Verification <i17YL1906> = 0.000000 passed13830 Verification <i17XY1907> = 0.000000 passed13830 Verification <i17YL1921> = 0 000000 passed

Assertion passed

13830 Verification <i17YL1921> = 0.000000 passed13830 # …13830 Closing test log after 0 mins 13.8 secs at Wed May 28 18:24:02 2003

0 Starting test 'D:\TB40\BOOKS\FLINT\PLC5\H1_BRNR.SCE' at Wed May 28 18:26:34 2003

Assertion Failed

y851 # …851 # … 17H-1 Start Main Burner Sequence851 # … Satisfy and Reset Fuel Gas Trip

ConclusionConclusionVP Link solves simulation needs from simple to sophisticated modeling in a continuous fashionOTS node can used as an engineering Test Bed system for preventive / periodical logic validationU tt d d R l Ti t i f lUnattended Real Time trainee performance logsModeling environment is flexible, easy to learn and maintain Lowest Total Cost of Ownership thanks to a non-invasive, I/O based simulationCost Effective simulation package for OTS And Validation, using Off the Shelf componentsCross platform functionalities makes VP Link aCross platform functionalities makes VP Link a durable , portable investment

Backup SlidesBackup Slides

Different Architectures for Different Architectures for ff fff fdifferent Applicationsdifferent Applications

Integrated Training or FAT Setup

Parallel Training Setup

Trainees operate different units, Trainees operate identical units,p ,interacting with each other

p ,in parallel