Data entry errors, time-consuming measurements, running around with clipboards and the fatal “fat finger” mistakes—these are just some of the problems encountered with manual testing and documentation. In a workshop Wednesday at Emerson Exchange 2010, speaker Ed Smigo of Proconex discussed a better system—using Syncade workflow software and AMS Device Manager to perform Safety Instrumented Systems (SIS) proof testing on a Delta V Smart SIS system.

Smigo’s talk focused on how SMART Instruments coupled with SMART Logic Solver and software tools can facilitate an automated test and documentation process that meets the IEC 61511 standard for good engineering work practices covering commissioning, validation, change control, documentation and on-going proof tests.

Syncade Smart Operations Management Suite is a group of software modules that extends the value of PlantWeb digital plant architecture by integrating real-time, intelligent plant-floor data with procedural, off-line and transactional plant business processes. Proconex, an Emerson Business Partner located in Philadelphia, developed the AMS QuickCheck snap-on module. Through a Web Services interface, QuickCheck becomes a conduit for any automated workflow steps from Syncade.

The Syncade workflow guides the operator through each step with paperless electronic work instructions. It automatically documents work performed and confirms that test values are within tolerance. The system includes automated error detection and a proof-test library with standard procedures.

Smigo showed examples of an interlock proof test before and after implementation of the Syncade automated process. In the before, a proof test required up to three separate technicians—one in the control room and two in the field—to run manual checks on valves and instruments, verify response and record data on clipboards.

After implementation of Syncade, the proof test can be run with one technician in the control room sitting at a Delta V screen and sending signals out to the SMART field instruments to validate instrument performance, physical wiring and software integrity.

If manufacturers make the capital commitment upfront to implement SMART instrumentation, they will reap the benefit of more accurate and faster commissioning down the road, Smigo noted, citing savings of up to one man-hour per device.