What are the best practices for documenting and reporting DCS simulation and testing activities?

The safety consequences for not doing this should be clearly stated for the management hierarchy and with regard to the legal issues and liabilities involved.

Defining the clear scope and objectives for DCS simulation and testing is essential. The scope must describe the system, functionalities and scenarios. Objectives must be SMART, indicating what you hope to achieve. Expected results include bug reports, performance reviews, and updated documentation. Success criteria must be established in advance, including requirements such as response time and regulatory compliance. Measuring results must be done using objective and qualitative metrics. Documenting everything is crucial to align expectations and ensure transparency.

Before going to simulate, I and my team always prepare a Simulation Test Sheet (as part of FAT document) as a base. The Simulation Test Sheet is created based on Control Narrative document and C&E document. By using that 2 documents as a minimum standard, you can measure and evaluate your result precisely. Don't forget to note the result in Simulation Test Sheet and share it with the related stakeholder.

Defining the system boundaries prior to start of simulation and testing leaves clearly identifies the test area. Clarify which DCS hardware/software and sub systems will be part of this activity. This also includes the communication protocols that are being used. Specify if the test environment is emulator based or on actual hardware. Specify what are the exclusions or what is out of the testing & simulation scope. Obtain consent from all stakeholders one the objectives and scopes have been enlisted.

Create an outline of what you need to validate and the validation test steps should be tested against a specification. If you are not testing against a specification consider why you are performing those test steps.

I do agree with the above explanations. Surjit Singh Ahuja Petroleum Engineer from Indian School of Mines, Dhanbad passed out in 1966.

In addition to following well-defined procedures, the qualification of the professionals involved is essential to guarantee the success of SDCD tests. Professionals must have solid technical knowledge in the area of distributed control, as well as experience in simulation and testing of complex systems. They must also be familiar with the specific tools and methodologies used in the testing process. Investing in adequate education and training of professionals is essential to ensure that they can perform testing tasks effectively and contribute to the quality and reliability of the system.

by using Simulation Test Sheet (as a part of FAT document), you can explain all the methodologies, scenarios, and the simulation tools that needed in simulation. for example if you want to simulate single loop control, the transmitter can be replaced by potentio-meter to simulate 4-20mA, the Control Valve can be replaced by Ampere-meter. If there is an discrete interlock in that single loop control, you can use SPST switch as a simulator.

It is essential to following a standard operating procedure when documenting your test results and issues. These issue should be filled out in standardized form and reviewed by someone other than the tester.

for simulation phase, I always test it internally before testing together with the client. I and my team always provide an internal test document and show it to client before doing official testing with the client. Deviations and Anomalies (if any) will be reported to client in a standard format which has been agreed by related stakeholder.

DCS Maintenance history should be documented. -Document and archive Software changes. -Keep a Maintenance dosier in each marshalling and control cabinet and update hardware changes. -Digitization techniques can also be adopted but in a secure manner. -Maintain an Engineer's logbook for recording any work done on DCS.

as I mentioned above in poin 1 to 3, you need to use Simulation Test Sheet as a base. Any abnormalities in the simulation phase can be easily identified (although it's hard to understand the abnormalities in some cases). But the important one is can be identified easily. for the analysis technique, you can use some methods such as Fault Tree Analysis, Why-Why Analysis, or Fish-Bone Diagram etc.

Depending on the type of testing that is being performed most of the documentation will be in the test protocol itself. By ensuring you have a well written protocol before testing you will not have to worry about missing as much information later on and possibly having to retest at a later date.

Below is what a DCS Engineer should do for Effective Communication of DCS Simulation and Testing Results: - Provide a concise overview of the simulation and testing process, highlighting key findings, achievements, challenges, and lessons learned. - Offer clear and specific recommendations for corrective actions, preventive measures, or improvement initiatives to address identified issues. - Utilize Flow charts, tables, diagrams, or screenshots to visually represent test results, facilitate comprehension, and strengthen the communication impact. - Encourage feedback and suggestions from team members, and clients. - Be consistent in DCS Programming, documentation, and to promote clarity.

Communicating DCS Test & simulation results is essential for record keeping and future reference. A well structured test and simulation report should be circulated to all stake holders including the project team, operations team and maintenance teams. Here's what needs to be included: 1) Test objective 2) Details of Test setup and simulators being used. What virtual environments were being considered, software emulators, signal generators etc. 3) Detailed results that include loop response times, Alarm and anunciation, communication reliability, HMI display etc. 4) Real time scenario tests for Input/output failure, power supply failure etc. 5) Result analysis and recommendations for improvement measures.

After analyzing the simulation, you can discuss about the result in wrap-up meeting. Of course the client need to involve in that wrap-up meeting. In the meeting, both of you (the vendor and the client) can discuss everything about the result. For example if your DCS has a connection to other 3rd party system (for example: Pakscan), you can discuss about the modbus parameter (addresses, baudrate, ID, etc). So when your system is installed in the area, you can just plug and play the DCS to 3rd party system because the parameter is synchronized.

Here are few insights beast on previous executed projects & learning from capital projects ICS FATs/SATs & Functional Testing: 1- To follow well defined proto-type testing for including application software by standardizing & defining the type of control blocks/devices controls/sequential programmed steps with descriptions within FLDs etc. After completion, testing & verification of proto-types Go-ahead for large scale implementation & testing. 2- Cross-Referencing shall be used to ensure consistency and traceability for associated pages & related documents. For example, link test cases to specific requirements, trace issues back to their root causes identified during analysis, and reference previous test results when relevant.

Based on my experience, there are 2 ways to do it. 1st: General DCS testing and validation - performance of common commands such as saving, opening, downloading, color-coding, forcing, bypass, inhibition, alarms, reset, etc. and other functions indicated on DCS functional design sepcifications. Any comments or discrepancy will be included in the punch list. 2nd: Individual testing and validation: Each tag should be documented such as indication, tagging, action, logic, PID control, range, color-coding, etc. Usually, you have a template form with listed variables to be ticked whether ok or not. All comments should be indicated on the document. Any discrepancy or error will be included in the punch list.

In the pharmaceutical industry it is essential to follow GAMP 5 which is a set of principles and procedures created to help validate automated computer systems for manufactured pharmaceutical products. Most of the reporting and documentation will happen naturally if these principles are followed.