ʻO ka hoʻāʻo hōʻoia he ʻāpana koʻikoʻi ia o ka mālama ʻana i ka pono palekana o kā mākou mau ʻōnaehana palekana i hoʻohana ʻia (SIS) a me nā ʻōnaehana e pili ana i ka palekana (e like me nā alarm koʻikoʻi, nā ʻōnaehana ahi a me ke kinoea, nā ʻōnaehana interlock i hoʻohana ʻia, a pēlā aku). ʻO ka hoʻāʻo hōʻoia he hoʻāʻo manawa ia e ʻike i nā hemahema weliweli, e hoʻāʻo i nā hana e pili ana i ka palekana (e like me ka hoʻonohonoho hou ʻana, nā bypasses, nā alarms, nā diagnostics, ka pani lima ʻana, a pēlā aku), a e hōʻoia i ka hoʻokō ʻana o ka ʻōnaehana i nā kūlana o ka hui a me waho. ʻO nā hopena o ka hoʻāʻo hōʻoia he ana hoʻi ia o ka pono o ka papahana pono mechanical SIS a me ka hilinaʻi kahua o ka ʻōnaehana.
Uhi nā kaʻina hana hoʻāʻo hōʻoia i nā ʻanuʻu hoʻāʻo mai ka loaʻa ʻana o nā palapala ʻae, ka hana ʻana i nā leka hoʻomaopopo a me ka wehe ʻana i ka ʻōnaehana mai ka lawelawe ʻana no ka hoʻāʻo ʻana a hiki i ka hōʻoia ʻana i ka hoʻāʻo piha, ka palapala ʻana i ka hoʻāʻo hōʻoia a me kāna mau hopena, ke hoʻihoʻi ʻana i ka ʻōnaehana i ka lawelawe, a me ka loiloi ʻana i nā hopena hoʻāʻo o kēia manawa a me nā hopena hoʻāʻo hōʻoia ma mua.
Uhi ʻo ANSI/ISA/IEC 61511-1, Paukū 16, i ka hoʻāʻo ʻana i ka hōʻoia SIS. Uhi ka hōʻike loea ISA TR84.00.03 - "Mechanical Integrity of Safety Instrumented Systems (SIS)," i ka hoʻāʻo ʻana i ka hōʻoia a ke hoʻoponopono hou ʻia nei me kahi mana hou e manaʻo ʻia e hoʻokuʻu koke ʻia. Ke hoʻomohala ʻia nei ka hōʻike loea ISA TR96.05.02 - "In-situ Proof Testing of Automated Valves".
ʻO ka hōʻike HSE UK CRR 428/2002 - "Nā loina no ka hoʻāʻo hōʻoia o nā ʻōnaehana palekana i hoʻokomo ʻia i nā mea hana ma ka ʻoihana kemika" hāʻawi i ka ʻike e pili ana i ka hoʻāʻo hōʻoia a me nā mea a nā ʻoihana e hana nei ma UK.
Hoʻokumu ʻia ke kaʻina hana hoʻāʻo hōʻoia ma kahi loiloi o nā ʻano hāʻule weliweli i ʻike ʻia no kēlā me kēia ʻāpana i ke ala huakaʻi hana palekana (SIF), ka hana SIF ma ke ʻano he ʻōnaehana, a pehea (a inā) e hoʻāʻo ai no ke ʻano hāʻule weliweli. Pono e hoʻomaka ka hoʻomohala ʻana i ke kaʻina hana ma ka pae hoʻolālā SIF me ka hoʻolālā ʻōnaehana, ke koho ʻana o nā ʻāpana, a me ka hoʻoholo ʻana i ka wā a pehea e hoʻāʻo ai. Loaʻa i nā mea hana SIS nā ʻano paʻakikī like ʻole o ka hoʻāʻo hōʻoia e pono e noʻonoʻo ʻia i ka hoʻolālā SIF, ka hana a me ka mālama ʻana. No ka laʻana, ʻoi aku ka maʻalahi o ka hoʻāʻo ʻana i nā mika orifice a me nā mea hoʻoili kaomi ma mua o nā mika kahe nui Coriolis, nā mika mag a i ʻole nā mea ʻike pae radar ma o ka ea. Hiki i ka hoʻopili a me ka hoʻolālā valve ke hoʻopilikia i ka piha o ka hoʻāʻo hōʻoia valve e hōʻoia i ka hiki ʻole o nā hāʻule weliweli a me ka hoʻomaka ʻana ma muli o ka degradation, plugging a i ʻole nā hāʻule e pili ana i ka manawa i kahi hāʻule koʻikoʻi i loko o ka manawa hoʻāʻo i koho ʻia.
ʻOiai ke hoʻomohala pinepine ʻia nā kaʻina hana hoʻāʻo hōʻoia i ka wā o ka ʻenekinia SIF, pono e loiloi ʻia e ka SIS Technical Authority, Operations a me nā mea hana loea e hana ana i ka hoʻāʻo. Pono hoʻi e hana i kahi loiloi palekana hana (JSA). He mea nui e loaʻa ka ʻae o ka hale hana i nā hoʻāʻo e hana ʻia a me ka wā, a me ko lākou hiki ke kino a me ka palekana. No ka laʻana, ʻaʻohe pono e wehewehe i ka hoʻāʻo hapa-hahau i ka wā ʻaʻole e ʻae ka hui Operations e hana. Manaʻo ʻia hoʻi e loiloi ʻia nā kaʻina hana hoʻāʻo hōʻoia e kahi loea kumuhana kūʻokoʻa (SME). Hōʻike ʻia ka hoʻāʻo maʻamau e pono ai no kahi hoʻāʻo hōʻoia hana piha ma ke Kiʻi 1.
Nā koi hoʻāʻo hōʻoia hana piha Kiʻi 1: Pono kahi kikoʻī hoʻāʻo hōʻoia hana piha no kahi hana i hoʻohana ʻia nā mea hana palekana (SIF) a me kāna ʻōnaehana i hoʻohana ʻia nā mea hana palekana (SIS) e wehewehe a kuhikuhi paha i nā ʻanuʻu ma ke kaʻina mai nā hoʻomākaukau hoʻāʻo a me nā kaʻina hana hoʻāʻo a hiki i nā leka hoʻomaopopo a me nā palapala.
Kiʻi 1: Pono kahi kikoʻī hoʻāʻo hōʻoia hana piha no kahi hana i hoʻohana ʻia nā mea hana palekana (SIF) a me kāna ʻōnaehana i hoʻohana ʻia nā mea hana palekana (SIS) e wehewehe a kuhikuhi paha i nā ʻanuʻu ma ke kaʻina mai nā hoʻomākaukau hoʻāʻo a me nā kaʻina hana hoʻāʻo a hiki i nā leka hoʻomaopopo a me nā palapala.
ʻO ka hoʻāʻo ʻana i ka hōʻoia he hana mālama i hoʻolālā ʻia e pono e hana ʻia e nā limahana akamai i hoʻomaʻamaʻa ʻia i ka hoʻāʻo ʻana o SIS, ke kaʻina hana hōʻoia, a me nā loop SIS a lākou e hoʻāʻo ai. Pono e hele wāwae i ke kaʻina hana ma mua o ka hana ʻana i ka hoʻāʻo hōʻoia mua, a me ka manaʻo i ka SIS Technical Authority ma hope no nā hoʻomaikaʻi a i ʻole nā hoʻoponopono.
Aia ʻelua mau ʻano hana hāʻule mua (palekana a pōʻino paha), i māhele ʻia i ʻehā mau ʻano hana—pōʻino i ʻike ʻole ʻia, pōʻino i ʻike ʻia (e nā diagnostics), palekana i ʻike ʻole ʻia a palekana i ʻike ʻia. Hoʻohana like ʻia nā huaʻōlelo hāʻule pōʻino a me pōʻino i ʻike ʻole ʻia ma kēia ʻatikala.
I ka hoʻāʻo ʻana i ka hōʻoia SIF, makemake nui mākou i nā ʻano hemahema weliweli i ʻike ʻole ʻia, akā inā he mau diagnostics mea hoʻohana e ʻike i nā hemahema weliweli, pono e hoʻāʻo ʻia kēia mau diagnostics. E hoʻomaopopo ʻaʻole like me nā diagnostics mea hoʻohana, ʻaʻole hiki ke hōʻoia ʻia nā diagnostics kūloko o ka hāmeʻa e like me ka hana e ka mea hoʻohana, a hiki i kēia ke hoʻololi i ke akeakamai hoʻāʻo hōʻoia. Ke lawe ʻia ka hōʻaiʻē no nā diagnostics i nā helu SIL, pono e hoʻāʻo ʻia nā alarms diagnostic (e laʻa me nā alarms ma waho o ka laulā) ma ke ʻano he ʻāpana o ka hoʻāʻo hōʻoia.
Hiki ke hoʻokaʻawale hou ʻia nā ʻano hāʻule i nā mea i hoʻāʻo ʻia no ka wā o kahi hoʻāʻo hōʻoia, nā mea i hoʻāʻo ʻole ʻia, a me nā hāʻule mua a i ʻole nā hāʻule e pili ana i ka manawa. ʻAʻole hiki ke hoʻāʻo pololei ʻia kekahi mau ʻano hāʻule weliweli no nā kumu like ʻole (e like me ka paʻakikī, ka hoʻoholo ʻenekinia a hana paha, ka naʻaupō, ka hiki ʻole, ka haʻalele ʻana a i ʻole ke kauoha ʻana i nā hewa ʻōnaehana, ka haʻahaʻa o ka hiki ʻana mai, a pēlā aku). Inā he mau ʻano hāʻule i ʻike ʻia ʻaʻole e hoʻāʻo ʻia, pono e hana ʻia ka uku ma ka hoʻolālā hāmeʻa, ke kaʻina hana hoʻāʻo, ka hoʻololi ʻana i nā hāmeʻa manawa a i ʻole ke kūkulu hou ʻana, a/a i ʻole ka hoʻāʻo inferencial e hana ʻia e hōʻemi i ka hopena ma ka pono o SIF o ka hoʻāʻo ʻole ʻana.
ʻO ka hemahema incipient he kūlana a kūlana paha e hōʻino ana i hiki ke manaʻo ʻia he hemahema koʻikoʻi a weliweli paha inā ʻaʻole i lawe ʻia nā hana hoʻoponopono i ka manawa kūpono. ʻIke pinepine ʻia lākou ma o ka hoʻohālikelike ʻana i ka hana me nā hoʻokolohua hōʻoia benchmark hou a mua paha (e like me nā pūlima valve a i ʻole nā manawa pane valve) a i ʻole ma ka nānā ʻana (e like me kahi puka hana i hoʻopaʻa ʻia). ʻO nā hemahema incipient e pili pinepine ana i ka manawa—ʻo ka lōʻihi o ka lawelawe ʻana o ka hāmeʻa a i ʻole ka hui ʻana, ʻoi aku ka hōʻino ʻia; ʻoi aku ka nui o nā kūlana e hoʻomaʻamaʻa ai i ka hemahema random, ke kāpili ʻana o ka puka hana a i ʻole ka hōʻiliʻili ʻana o ka sensor i ka hala ʻana o ka manawa, ua pau ke ola pono, a pēlā aku. No laila, ʻo ka lōʻihi o ka manawa hoʻāʻo hōʻoia, ʻoi aku ka nui o ka hemahema incipient a i ʻole ka manawa. Pono e hoʻāʻo ʻia nā pale āpau e kūʻē i nā hemahema incipient (port purging, heat tracing, etc.).
Pono e kākau ʻia nā kaʻina hana e hoʻāʻo i ka hōʻoia no nā hemahema weliweli (ʻike ʻole ʻia). Hiki i nā ʻenehana Failure Mode and Effect Analysis (FMEA) a i ʻole Failure Mode, Effect and Diagnosis Analysis (FMEDA) ke kōkua i ka ʻike ʻana i nā hemahema weliweli i ʻike ʻole ʻia, a ma hea e pono ai ke hoʻomaikaʻi ʻia ka uhi ʻana o ka hōʻoia.
He nui nā kaʻina hana hoʻāʻo hōʻoia i kākau ʻia ma muli o ka ʻike a me nā template mai nā kaʻina hana e kū nei. Ke koi nei nā kaʻina hana hou a me nā SIF paʻakikī i kahi ala ʻenekinia hou e hoʻohana ana i ka FMEA/FMEDA e kālailai no nā hemahema weliweli, e hoʻoholo pehea e hoʻāʻo ai ke kaʻina hana hoʻāʻo no kēlā mau hemahema, a me ka uhi ʻana o nā hoʻāʻo. Hōʻike ʻia kahi kiʻikuhi poloka loiloi mode hemahema macro-level no kahi sensor ma ke Kiʻi 2. ʻO ka FMEA maʻamau e hana ʻia i hoʻokahi manawa no kahi ʻano hāmeʻa a hoʻohana hou ʻia no nā hāmeʻa like me ka noʻonoʻo ʻana i kā lākou lawelawe hana, hoʻonohonoho a me nā hiki ke hoʻāʻo kahua.
Ka loiloi hemahema pae macro Kiʻi 2: Hōʻike kēia kiʻikuhi poloka loiloi ʻano hemahema pae macro no kahi sensor a me ka mea hoʻoili kaomi (PT) i nā hana nui e wāwahi pinepine ʻia i loko o nā loiloi hemahema micro he nui e wehewehe piha i nā hemahema hiki ke hoʻoponopono ʻia i nā hoʻokolohua hana.
Kiʻi 2: Hōʻike kēia kiʻikuhi poloka loiloi ʻano hāʻule macro-level no kahi sensor a me ka mea hoʻoili kaomi (PT) i nā hana nui e wāwahi pinepine ʻia i loko o nā loiloi hāʻule micro he nui e wehewehe piha i nā hāʻule hiki ke hoʻoponopono ʻia i nā hoʻokolohua hana.
ʻO ka pakeneka o nā hemahema i ʻike ʻia, weliweli, a ʻike ʻole ʻia i hoʻāʻo ʻia no ka hōʻoia ʻana ua kapa ʻia ʻo ka uhi hoʻāʻo hōʻoia (PTC). Hoʻohana pinepine ʻia ka PTC i nā helu SIL e "uku" no ka hiki ʻole ke hoʻāʻo piha i ka SIF. Loaʻa i ka poʻe ka manaʻo kuhihewa no ka mea ua noʻonoʻo lākou i ka nele o ka uhi hoʻāʻo i kā lākou helu SIL, ua hoʻolālā lākou i kahi SIF hilinaʻi. ʻO ka ʻoiaʻiʻo maʻalahi, inā he 75% kāu uhi hoʻāʻo, a inā ʻoe i hoʻokomo i kēlā helu i kāu helu SIL a hoʻāʻo i nā mea āu e hoʻāʻo pinepine nei, hiki nō i ka 25% o nā hemahema weliweli ke hana ʻia ma ke ʻano helu. ʻAʻole maopopo iaʻu makemake e noho i loko o kēlā 25%.
ʻO ka maʻamau, hāʻawi nā hōʻike ʻae a ka FMEDA a me nā puke lima palekana no nā hāmeʻa i kahi kaʻina hana hoʻāʻo hōʻoia liʻiliʻi loa a me ka uhi ʻana o ka hoʻāʻo hōʻoia. Hāʻawi kēia i ke alakaʻi wale nō, ʻaʻole nā ʻanuʻu hoʻāʻo āpau e pono ai no kahi kaʻina hana hoʻāʻo hōʻoia piha. Hoʻohana ʻia nā ʻano loiloi hāʻule ʻē aʻe, e like me ka loiloi lāʻau hewa a me ka mālama pono ʻana, e kālailai no nā hāʻule weliweli.
Hiki ke hoʻokaʻawale ʻia nā hoʻāʻo hōʻoia i ka hana piha (hopena a i ka hopena) a i ʻole ka hoʻāʻo hana hapa (Kiʻi 3). Hana pinepine ʻia ka hoʻāʻo hana hapa i ka wā e loaʻa ai i nā ʻāpana o ka SIF nā manawa hoʻāʻo like ʻole i nā helu SIL i kūlike ʻole me nā pani i hoʻolālā ʻia a i ʻole nā hoʻohuli. He mea nui e hoʻopili ʻia nā kaʻina hana hoʻāʻo hōʻoia hana hapa i mea e hoʻāʻo pū ai lākou i nā hana palekana āpau o ka SIF. Me ka hoʻāʻo hana hapa, ua ʻōlelo ʻia e loaʻa i ka SIF kahi hoʻāʻo hōʻoia mua mai ka hopena a i ka hopena, a me nā mea ma hope i ka wā o nā hoʻohuli.
Pono e hoʻohui ʻia nā hoʻāʻo hōʻoia hapa Kiʻi 3: Pono nā hoʻāʻo hōʻoia hapa i hui pū ʻia (lalo) e uhi i nā hana āpau o kahi hoʻāʻo hōʻoia hana piha (luna).
Kiʻi 3: Pono nā hoʻāʻo hōʻoia hapa i hui pū ʻia (lalo) e uhi i nā hana āpau o kahi hoʻāʻo hōʻoia hana piha (luna).
Hoʻāʻo wale ka hoʻāʻo hōʻoia hapa i kahi pakeneka o nā ʻano hāʻule o kahi hāmeʻa. ʻO kahi laʻana maʻamau ka hoʻāʻo ʻana i ka valve hapa-stroke, kahi e hoʻoneʻe ʻia ai ka valve i kahi liʻiliʻi (10-20%) e hōʻoia ʻaʻole ia i paʻa. He haʻahaʻa ka uhi hoʻāʻo hōʻoia o kēia ma mua o ka hoʻāʻo hōʻoia ma ka wā hoʻāʻo mua.
Hiki ke ʻokoʻa ka paʻakikī o nā kaʻina hana hoʻāʻo hōʻoia me ka paʻakikī o ka SIF a me ke akeakamai o ke kaʻina hana hoʻāʻo o ka hui. Kākau kekahi mau ʻoihana i nā kaʻina hana hoʻāʻo kikoʻī, aʻo kekahi he mau kaʻina hana pōkole. Hoʻohana ʻia nā kuhikuhi i nā kaʻina hana ʻē aʻe, e like me ka calibration maʻamau, i kekahi manawa e hōʻemi i ka nui o ke kaʻina hana hoʻāʻo hōʻoia a e kōkua i ka hōʻoia ʻana i ke kūlike i ka hoʻāʻo ʻana. Pono kahi kaʻina hana hoʻāʻo hōʻoia maikaʻi e hāʻawi i nā kikoʻī lawa e hōʻoia i ka hoʻokō pono ʻia a me ka palapala ʻia ʻana o nā hoʻāʻo āpau, akā ʻaʻole nui ka kikoʻī e hoʻoulu ai i nā loea e makemake e hōʻalo i nā ʻanuʻu. ʻO ka loaʻa ʻana o ka loea, nāna ke kuleana no ka hana ʻana i ke kaʻina hana hoʻāʻo, e hoʻomaka i ke kaʻina hana hoʻāʻo i hoʻopau ʻia e kōkua i ka hōʻoia ʻana e hana pololei ʻia ka hoʻāʻo. ʻO ke kau inoa ʻana o ka hoʻāʻo hōʻoia i hoʻopau ʻia e ka Luna Hoʻomalu Mea Hana a me nā ʻelele Hana e hoʻokūpaʻa pū i ke koʻikoʻi a hōʻoia i kahi hoʻāʻo hōʻoia i hoʻopau pono ʻia.
Pono e kono mau ʻia nā manaʻo o ka loea e kōkua i ka hoʻomaikaʻi ʻana i ke kaʻina hana. ʻO ka holomua o kahi kaʻina hana hoʻāʻo hōʻoia e kau nui ʻia ana ma nā lima o ka loea, no laila paipai nui ʻia ka hana hui pū ʻana.
ʻO ka hapa nui o nā hoʻāʻo hōʻoia e hana ʻia ma waho o ka pūnaewele i ka wā o ka pani ʻana a i ʻole ka hoʻohuli ʻana. I kekahi mau hihia, pono paha e hana ʻia ka hoʻāʻo hōʻoia ma ka pūnaewele i ka wā e holo ana e hoʻokō i nā helu SIL a i ʻole nā koi ʻē aʻe. Pono ka hoʻāʻo pūnaewele i ka hoʻolālā a me ka hoʻonohonoho ʻana me nā Operations e ʻae i ka hoʻāʻo hōʻoia e hana palekana, me ka ʻole o ka hoʻopilikia ʻana o ke kaʻina hana, a me ka ʻole o ka hoʻoulu ʻana i kahi huakaʻi spurious. Hoʻokahi wale nō huakaʻi spurious e hoʻohana ai i kāu mau attaboys āpau. I loko o kēia ʻano hoʻāʻo, i ka wā ʻaʻole i loaʻa piha ka SIF e hana i kāna hana palekana, 61511-1, Paukū 11.8.5, ʻōlelo ʻia "E hāʻawi ʻia nā hana uku e hōʻoia i ka hoʻomau ʻana o ka hana palekana e like me 11.3 i ka wā e bypass ai ka SIS (hoʻoponopono a hoʻāʻo paha)." Pono e hele pū kahi kaʻina hana hoʻokele kūlana maʻamau me ke kaʻina hana hoʻāʻo hōʻoia e kōkua i ka hōʻoia ʻana i ka hana pono ʻana o kēia.
ʻO ka maʻamau, ua māhele ʻia kahi SIF i ʻekolu mau ʻāpana nui: nā mea ʻike, nā mea hoʻonā logic a me nā mea hope loa. Aia pū kekahi mau mea kōkua maʻamau e hiki ke hoʻopili ʻia i loko o kēlā me kēia o kēia mau ʻāpana ʻekolu (e like me nā pale IS, nā amp trip, nā relay interposing, nā solenoids, a me nā mea ʻē aʻe) pono e hoʻāʻo ʻia. Hiki ke loaʻa nā ʻano koʻikoʻi o ka hoʻāʻo hōʻoia i kēlā me kēia o kēia mau ʻenehana ma ka ʻaoʻao ʻaoʻao, "Nā mea hoʻāʻo hoʻāʻo, nā mea hoʻonā logic a me nā mea hope loa" (ma lalo).
ʻOi aku ka maʻalahi o ka hoʻāʻo ʻana i kekahi mau mea ma mua o nā mea ʻē aʻe. He nui nā ʻenehana kahe a me ka pae hou a me kekahi mau ʻenehana kahiko i loko o ka māhele paʻakikī. ʻO kēia mau mea nā mika kahe Coriolis, nā mika vortex, nā mika mag, ka radar ma o ka lewa, ka pae ultrasonic, a me nā kuapo hana in-situ, e inoa i kekahi mau mea. ʻO ka mea pōmaikaʻi, he nui o kēia mau mea i loaʻa i nā diagnostics i hoʻomaikaʻi ʻia e hiki ai ke hoʻāʻo maikaʻi ʻia.
Pono e noʻonoʻo ʻia ka paʻakikī o ka hoʻāʻo ʻana i kēlā ʻano mea hana ma ke kahua i ka hoʻolālā SIF. He mea maʻalahi no ka ʻenekinia ke koho i nā mea hana SIF me ka noʻonoʻo pono ʻole i ka mea e pono ai e hoʻāʻo i ka mea hana, ʻoiai ʻaʻole lākou e lilo i poʻe e hoʻāʻo nei iā lākou. He ʻoiaʻiʻo nō hoʻi kēia no ka hoʻāʻo ʻana i ka hapa-hahau, he ala maʻamau ia e hoʻomaikaʻi ai i ka awelika SIF o ka hāʻule ʻana ma ke koi (PFDavg), akā ma hope aku, ʻaʻole makemake ka hana o ka hale hana e hana ia mea, a i nā manawa he nui ʻaʻole paha. E hāʻawi mau i ka nānā ʻana o ka hale hana i ka ʻenekinia o nā SIF e pili ana i ka hoʻāʻo ʻana i ka hōʻoia.
Pono e komo pū ka hoʻāʻo hōʻoia i kahi nānā ʻana o ke kau ʻana a me ka hoʻoponopono ʻana o ka SIF e like me ka mea e pono ai e hoʻokō i ka 61511-1, Paukū 16.3.2. Pono e hana ʻia kahi nānā hope loa e hōʻoia i ka hoʻonohonoho pono ʻia ʻana o nā mea āpau, a me kahi nānā pālua ua hoʻihoʻi pono ʻia ka SIF i loko o ka lawelawe hana.
ʻO ke kākau ʻana a me ka hoʻokō ʻana i kahi kaʻina hana hoʻāʻo maikaʻi he hana nui ia e hōʻoia i ka pono o ka SIF i kona wā e ola ana. Pono ke kaʻina hana hoʻāʻo e hāʻawi i nā kikoʻī lawa e hōʻoia i ka hana mau ʻia a me ka palekana o nā hoʻāʻo e pono ai a hoʻopaʻa ʻia. Pono e uku ʻia nā hemahema weliweli i hoʻāʻo ʻole ʻia e nā hoʻāʻo hōʻoia e hōʻoia i ka mālama pono ʻia o ka pono o ka SIF i kona wā e ola ana.
ʻO ke kākau ʻana i kahi kaʻina hana hoʻāʻo hōʻoia maikaʻi e pono ai kahi ala kūpono i ka loiloi ʻenekinia o nā hemahema weliweli hiki ke loaʻa, ke koho ʻana i nā ʻano hana, a me ke kākau ʻana i nā ʻanuʻu hoʻāʻo hōʻoia i loko o nā hiki ke hoʻāʻo o ka hale hana. Ma ke ala, e kiʻi i ke kūʻai ʻana o ka hale hana ma nā pae āpau no ka hoʻāʻo ʻana, a e hoʻomaʻamaʻa i nā loea e hana a hoʻopaʻa i ka hoʻāʻo hōʻoia a me ka hoʻomaopopo ʻana i ke koʻikoʻi o ka hoʻāʻo. E kākau i nā kuhikuhi me he mea lā ʻo ʻoe ke loea mea hana e hana i ka hana, a hilinaʻi kēlā ola i ka loaʻa ʻana o ka hoʻāʻo pololei, no ka mea, hana lākou.
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
ʻO ka maʻamau, ua māhele ʻia kahi SIF i ʻekolu mau ʻāpana nui, nā mea ʻike, nā mea hoʻonā logic a me nā mea hope loa. Aia pū kekahi mau mea kōkua e hiki ke hoʻopili ʻia i loko o kēlā me kēia o kēia mau ʻāpana ʻekolu (e like me nā pale IS, nā amp trip, nā relay interposing, nā solenoids, a me nā mea ʻē aʻe) pono e hoʻāʻo ʻia.
Nā hoʻāʻo hōʻoia sensor: Pono ka hoʻāʻo hōʻoia sensor e hōʻoia i ka hiki i ka sensor ke ʻike i ke ʻano o ke kaʻina hana ma luna o kona laulā piha a hoʻouna i ka hōʻailona kūpono i ka mea hoʻonā logic SIS no ka loiloi. ʻOiai ʻaʻole i hoʻokomo pū ʻia, ua hāʻawi ʻia kekahi o nā mea e noʻonoʻo ai i ka hana ʻana i ka ʻāpana sensor o ke kaʻina hana hoʻāʻo hōʻoia ma ka Papa 1.
Hoʻāʻo hōʻoia logic solver: Ke hana ʻia ka hoʻāʻo hōʻoia hana piha, hoʻāʻo ʻia ka hana a ka logic solver i ka hoʻokō ʻana i ka hana palekana o ka SIF a me nā hana pili (e like me nā alarms, reset, bypasses, diagnostics mea hoʻohana, redundancies, HMI, etc.). Pono nā hoʻāʻo hōʻoia hana hapa a ʻāpana paha e hoʻokō i kēia mau hoʻāʻo āpau ma ke ʻano he ʻāpana o nā hoʻāʻo hōʻoia overlapping pākahi. Pono ka mea hana logic solver e loaʻa i kahi kaʻina hana hoʻāʻo hōʻoia i ʻōlelo ʻia ma ka manual palekana hāmeʻa. Inā ʻaʻole a ma ka liʻiliʻi loa, pono e hoʻololi ʻia ka mana logic solver, a pono e nānā ʻia nā registers diagnostic solver, nā kukui kūlana, nā voltages lako mana, nā loulou kamaʻilio a me ka redundancy. Pono e hana ʻia kēia mau nānā ma mua o ka hoʻāʻo hōʻoia hana piha.
Mai kuhi ʻoe he maikaʻi ka polokalamu no ka wā pau ʻole a ʻaʻole pono e hoʻāʻo ʻia ke kumu ma hope o ka hoʻāʻo hōʻoia mua ʻana no ka mea hiki i nā loli polokalamu a me nā lako paʻa i palapala ʻole ʻia, ʻae ʻole ʻia a hoʻāʻo ʻole ʻia a hiki ke komo i loko o nā ʻōnaehana i ka hala ʻana o ka manawa a pono e noʻonoʻo ʻia i loko o kāu ʻano hoʻāʻo hōʻoia holoʻokoʻa. Pono e nānā hou ʻia ka hoʻokele ʻana i nā hoʻololi, mālama, a me nā moʻolelo hoʻoponopono e hōʻoia i ka hōʻano hou ʻia a mālama pono ʻia, a inā hiki, pono e hoʻohālikelike ʻia ka polokalamu noi me ka waihona kope hou loa.
Pono hoʻi e mālama pono ʻia e hoʻāʻo i nā hana kōkua a me nā hana diagnostic a ka mea hoʻoponopono logic mea hoʻohana (e like me nā ʻīlio kiaʻi, nā loulou kamaʻilio, nā pono hana cybersecurity, a me nā mea ʻē aʻe).
Hoʻāʻo hōʻoia hope loa: ʻO ka hapa nui o nā mea hope loa he mau valves, akā naʻe, hoʻohana ʻia nā mea hoʻomaka motika o nā lako wili, nā hoʻokele wikiwiki loli a me nā ʻāpana uila ʻē aʻe e like me nā mea hoʻopili a me nā mea haki kaapuni ma ke ʻano he mau mea hope loa a pono e kālailai ʻia ko lākou mau ʻano hāʻule a hoʻāʻo ʻia ka hōʻoia.
ʻO nā ʻano hana hāʻule mua no nā valves ka paʻa ʻana, ka lohi loa o ka manawa pane a i ʻole ka wikiwiki loa, a me ka leakage, nā mea a pau i hoʻopilikia ʻia e ka pilina hana o ka valve i ka manawa huakaʻi. ʻOiai ʻo ka hoʻāʻo ʻana i ka valve ma nā kūlana hana ka hihia makemake nui ʻia, ʻo ka hana maʻamau e kūʻē i ka hoʻohiolo ʻana i ka SIF i ka wā e hana ana ka mea kanu. Hoʻāʻo pinepine ʻia ka hapa nui o nā valves SIS i ka wā e iho ana ka mea kanu ma ka ʻole o ke kaomi ʻokoʻa, ʻo ia ka mea liʻiliʻi loa o nā kūlana hana. Pono ka mea hoʻohana e makaʻala i ke kaomi ʻokoʻa hana ʻino loa a me nā hopena hōʻino valve a me ke kaʻina hana, pono e noʻonoʻo ʻia i loko o ka hoʻolālā valve a me ka actuator a me ka nui.
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).
Hiki i nā mahana ambient ke hoʻopilikia i nā ukana friction valve, no laila ʻo nā valves hoʻāʻo i ka wā mahana e lilo i ka ukana friction liʻiliʻi loa i ka hoʻohālikelike ʻia me ka hana anuanu. ʻO ka hopena, pono e noʻonoʻo ʻia ka hoʻāʻo hōʻoia o nā valves ma kahi mahana kūlike e hāʻawi i ka ʻikepili kūlike no ka hoʻāʻo inferential no ka hoʻoholo ʻana i ka hōʻino ʻana o ka hana valve.
ʻO nā valves me nā mea hoʻonoho akamai a i ʻole kahi mea hoʻokele valve kikohoʻe ma ke ʻano laulā he hiki ke hana i kahi pūlima valve hiki ke hoʻohana ʻia e nānā i ka hōʻino ʻana i ka hana valve. Hiki ke noi ʻia kahi pūlima valve baseline ma ke ʻano he ʻāpana o kāu kauoha kūʻai a i ʻole hiki iā ʻoe ke hana i hoʻokahi i ka wā o ka hoʻāʻo hōʻoia mua e lawelawe ma ke ʻano he baseline. Pono e hana ʻia ka pūlima valve no ka wehe ʻana a me ka pani ʻana o ka valve. Pono hoʻi e hoʻohana ʻia ka diagnostic valve holomua inā loaʻa. Hiki i kēia ke kōkua iā ʻoe e haʻi iā ʻoe inā e hōʻino ana kāu hana valve ma ka hoʻohālikelike ʻana i nā pūlima valve hoʻāʻo hōʻoia ma hope a me nā diagnostics me kāu baseline. Hiki i kēia ʻano hoʻāʻo ke kōkua i ka uku ʻana no ka hoʻāʻo ʻole ʻana i ka valve ma nā kaomi hana ʻino loa.
Hiki paha i ka pūlima valve i ka wā o kahi hoʻāʻo hōʻoia ke hoʻopaʻa i ka manawa pane me nā hōʻailona manawa, e wehe ana i ka pono no kahi stopwatch. ʻO ka hoʻonui ʻia o ka manawa pane he hōʻailona ia o ka hōʻino ʻana o ka valve a me ka hoʻonui ʻia o ka ukana friction e hoʻoneʻe i ka valve. ʻOiai ʻaʻohe kūlana e pili ana i nā loli i ka manawa pane valve, ʻo kahi ʻano maikaʻi ʻole o nā loli mai ka hoʻāʻo hōʻoia i ka hoʻāʻo hōʻoia e hōʻike ana i ka nalowale o ka palena palekana a me ka hana o ka valve. Pono ka hoʻāʻo hōʻoia valve SIS hou e hoʻokomo i kahi pūlima valve ma ke ʻano he hana ʻenekinia maikaʻi.
Pono e ana ʻia ke kaomi hoʻolako ea o ka mea hana valve i ka wā o kahi hoʻāʻo hōʻoia. ʻOiai ʻo ka pūnāwai valve no ka valve hoʻihoʻi puna ka mea e pani ai i ka valve, ua hoʻoholo ʻia ka ikaika a i ʻole ka torque i komo e ka nui o ke kaomi ʻana o ka pūnāwai valve e ke kaomi hoʻolako valve (e like me ke kānāwai o Hooke, F = kX). Inā haʻahaʻa kāu kaomi hoʻolako, ʻaʻole e kaomi nui ka pūnāwai, no laila e emi ka ikaika e loaʻa e hoʻoneʻe i ka valve i ka wā e pono ai. ʻOiai ʻaʻole i hoʻokomo ʻia, ua hāʻawi ʻia kekahi o nā mea e noʻonoʻo ai i ka hana ʻana i ka ʻāpana valve o ke kaʻina hana hoʻāʻo hōʻoia ma ka Papa 2.
Ka manawa hoʻouna: Nov-13-2019