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ToolFusion / Chemical Injection Skid / Engineering Tools

Project Tool: Control System Validation for Chemical Injection Skids

Specification & Integration Verification

F6 Composition for Control System Validation for Chemical Injection Skids

● Not Golden Verified ● Project Trust Verified Runnable: 6 / 9 steps
VERIFIED SCOPE
○ Calculate PFD_avg for 1oo2 architecture with common cause CALCULATION Runnable
○ Map PFD_avg to SIL level PASS / FAIL capable Runnable
○ Verify PFD_avg ≤ 1.0e-2 for SIL 2 target PASS / FAIL capable Runnable
○ Perform pairwise interlock condition equivalence check CALCULATION Manual Workflow
○ Calculate achievable UPS runtime at 25°C, new battery CALCULATION Runnable
○ Apply temperature and aging derating to runtime CALCULATION Runnable
○ Verify derated runtime ≥ 15 min + 25% safety margin PASS / FAIL capable Runnable
○ Extract required detection/mitigation paths from HAZOP record CALCULATION Manual Workflow
○ Match executed tests to required paths CALCULATION Input Required
⚠ This tool does not currently verify Interlock Logic Consistency Assessment.
PROJECT INPUTS

Runnable deterministic steps: 6 / 9. Enter the project conditions used by this verification workflow. Prefilled values (17/23 inputs) are demonstration inputs, not recommended design values.

01Step 1: Calculate PFD_avg for 1oo2 architecture with common causeFormula
failures/hour
hours
dimensionless
dimensionless
Quantify the average probability that the SIF fails to perform its safety function when demanded, enabling SIL verifi...
02Step 2: Map PFD_avg to SIL levelValidation Rule
dimensionless
Translate calculated PFD_avg into discrete SIL rating per IEC 61508-1 Table 3 for conformance assessment.
03Step 3: Verify PFD_avg ≤ 1.0e-2 for SIL 2 targetValidation Rule
Confirm design meets minimum safety integrity requirement for SIL 2.
04Step 4: Perform pairwise interlock condition equivalence checkManual Workflow
set_of_boolean_conditions
set_of_boolean_conditions
Detect divergent enable/disable logic across control layers that could lead to unsafe operation or nuisance trips.
05Step 5: Calculate achievable UPS runtime at 25°C, new batteryFormula
ampere_hours
volts
watts
ampere_hours
volts
watts
Determine base runtime before applying environmental and life-cycle deratings.
06Step 6: Apply temperature and aging derating to runtimeFormula
minutes
dimensionless
dimensionless
minutes
dimensionless
dimensionless
Adjust nominal runtime to reflect real-world operational constraints.
07Step 7: Verify derated runtime ≥ 15 min + 25% safety marginValidation Rule
Ensure UPS sustains control functions through full outage plus contingency.
08Step 8: Extract required detection/mitigation paths from HAZOP re...Manual Workflow
structured_record
Identify all engineered responses mandated for the specific deviation to guide test completeness assessment.
09Step 9: Match executed tests to required pathsFormula
set_of_detection_methods
set_of_mitigation_actions
set_of_test_cases
Quantify test coverage and identify unvalidated safety functions.

⚠ Runnable deterministic steps: 6 / 9. Steps marked "Input Required" or "Example Input Required" need user-provided engineering values before calculation.

Deterministic calculation · Results become stale when engineering inputs change.
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ENGINEERING EVIDENCE

Golden Coverage0 / 9
Project Trust11 / 11 PASS
RuntimeDeterministic
Components0 small tools, 9 steps

SCOPE & LIMITATIONS

NOT CURRENTLY VERIFIED
○ Interlock Logic Consistency Assessment
These capabilities are outside the current verified workflow.

HOW THIS VERIFICATION WORKS

  1. Step 1: Calculate PFD_avg for 1oo2 architecture with common cause — performs a deterministic calculation from the provided inputs. No acceptance criterion is applied; the result is CALCULATED only.
  2. Step 2: Map PFD_avg to SIL level — compares engineering inputs against deterministic thresholds and produces a PASS or FAIL decision.
  3. Step 3: Verify PFD_avg ≤ 1.0e-2 for SIL 2 target — compares engineering inputs against deterministic thresholds and produces a PASS or FAIL decision.
  4. Step 4: Perform pairwise interlock condition equivalence check — engineering workflow step. Follow the documented method for manual execution.
  5. Step 5: Calculate achievable UPS runtime at 25°C, new battery — performs a deterministic calculation from the provided inputs. No acceptance criterion is applied; the result is CALCULATED only.
  6. Step 6: Apply temperature and aging derating to runtime — performs a deterministic calculation from the provided inputs. No acceptance criterion is applied; the result is CALCULATED only.
  7. Step 7: Verify derated runtime ≥ 15 min + 25% safety margin — compares engineering inputs against deterministic thresholds and produces a PASS or FAIL decision.
  8. Step 8: Extract required detection/mitigation paths from HAZOP record — engineering workflow step. Follow the documented method for manual execution.
  9. Step 9: Match executed tests to required paths — performs a deterministic calculation from the provided inputs. No acceptance criterion is applied; the result is CALCULATED only.

This tool coordinates 3 validation steps and 6 calculation steps. The overall engineering decision uses ALL_REQUIRED_VALIDATION_PASS aggregation: only validation steps contribute to the pass/fail outcome; calculation steps produce data only.

METHODS & EQUATIONS

All formulas are resolved from canonical runtime definitions and executed deterministically by the client-side engine.

Step 1: Calculate PFD_avg for 1oo2 architecture with common cause

Formula(failure_rate_dangerous_hidden * (1 - proof_test_coverage) * proof_test_interval / 2 + common_cause_factor * failure_rate_dangerous_hidden * proof_test_interval)^2 + failure_rate_dangerous_hidden * (1 - proof_test_coverage) * proof_test_interval / 2

Step 2: Map PFD_avg to SIL level

Validation Rule
PFD_avg <= 1 [engineering_standard:IEC_61508-1:2010_Table_3]; and > 1 [engineering_standard:IEC_61508-1:2010_Table_3]; if <= 1 [engineering_standard:IEC_61508-1:2010_Table_3]; and > 1 [engineering_standard:IEC_61508-1:2010_Table_3]

Step 3: Verify PFD_avg ≤ 1.0e-2 for SIL 2 target

Validation Rule
PFD_avg <= 0.01 [engineering_standard:IEC_61508-1:2010 Table 3]

Step 4: Perform pairwise interlock condition equivalence check

Manual Workflow
For each interlock condition group (e.g., 'valve_open_permit'), extract all Boolean expressions from DCS, PLC, and local panel documentation; normalize variable names and logic operators; compare expression equivalence using symbolic simplification (e.g., De Morgan’s laws); flag non-equivalent conditions as conflicts with root cause annotation (e.g., 'manual_override_enabled ≠ auto_mode_active → mode mismatch').

Step 5: Calculate achievable UPS runtime at 25°C, new battery

Formula(C_bat*V_bat/P_load)*60

Step 6: Apply temperature and aging derating to runtime

Formulat_run*k_temp*k_age

Step 7: Verify derated runtime ≥ 15 min + 25% safety margin

Validation Rule
achievable_runtime >= 18.75 [verified_design_rule:25]

Step 8: Extract required detection/mitigation paths from HAZOP record

Manual Workflow
Parse HAZOP worksheet field 'Detection Methods' and 'Recommended Actions' to extract discrete, testable detection mechanisms and mitigation actions; normalize terminology (e.g., 'XV-201' → 'isolation_valve_close'); output as enumerated sets.

Step 9: Match executed tests to required paths

FormulaFor each item in RDP ∪ RMA, check presence of corresponding test in FT_executed using exact string match after normalization (e.g., 'XV-201 close' ↔ 'isolation_valve_close'); compute CR = (matched_count / total_required_count); list unmatched items as gaps.

UNDERSTANDING THE RESULTS

PASS
A proven validation criterion passed. The engineering input satisfies the deterministic threshold.
FAIL
A proven validation criterion failed. The engineering input does not satisfy the deterministic threshold.
CALCULATED
A deterministic calculation completed, but no acceptance criterion exists for this step. CALCULATED does NOT mean PASS.
RESULT NOT VALID
Runtime executed but engineering validity requirements were not met.
INCOMPLETE
Required inputs or workflow steps are incomplete.

The overall decision reflects only validation steps. Calculation steps produce numerical results without pass/fail claims.

WHEN TO USE THIS TOOL

  • When deterministic Chemical Injection Skid engineering verification is needed for project-specific conditions.
  • For calculation of Calculate PFD_avg for 1oo2 architecture with common cause (Step 1).
  • For validation of Map PFD_avg to SIL level (Step 2).
  • For validation of Verify PFD_avg ≤ 1.0e-2 for SIL 2 target (Step 3).
  • For calculation of Perform pairwise interlock condition equivalence check (Step 4).
  • For calculation of Calculate achievable UPS runtime at 25°C, new battery (Step 5).
  • For calculation of Apply temperature and aging derating to runtime (Step 6).
  • For validation of Verify derated runtime ≥ 15 min + 25% safety margin (Step 7).
  • For calculation of Extract required detection/mitigation paths from HAZOP record (Step 8).
  • For calculation of Match executed tests to required paths (Step 9).
  • For deterministic pre-checks before formal engineering review or submission.

When NOT to use this tool: This tool does not replace laboratory testing, formal engineering analysis by a licensed professional, or code-compliance certification. It performs deterministic threshold comparison and calculation only.

ENGINEERING FAQ

What does this verification tool check?

This tool performs 9 deterministic engineering steps: (1) Calculate PFD_avg for 1oo2 architecture with common cause, (2) Map PFD_avg to SIL level, (3) Verify PFD_avg ≤ 1.0e-2 for SIL 2 target, (4) Perform pairwise interlock condition equivalence check, (5) Calculate achievable UPS runtime at 25°C, new battery, (6) Apply temperature and aging derating to runtime, (7) Verify derated runtime ≥ 15 min + 25% safety margin, (8) Extract required detection/mitigation paths from HAZOP record, (9) Match executed tests to required paths.

What does a PASS result mean?

A PASS result means the validation step's deterministic threshold comparison was satisfied. It does not constitute laboratory certification or code compliance.

What does a CALCULATED result mean?

A CALCULATED result means the deterministic calculation completed, but no acceptance criterion is applied to this step. CALCULATED does NOT mean PASS.

What is not currently verified by this workflow?

Capabilities not currently verified include: Interlock Logic Consistency Assessment.

How many steps are golden verified?

0 out of 9 steps have been verified with deterministic golden test cases.

COMPONENT TOOLS

This workflow currently contains no bound executable Small Tools. Steps are defined by engineering methods and reference materials.

CalculationWorkflow StepVerify SIL compliance of emergency shutdown logic for chemical injection pump
ValidationWorkflow StepVerify SIL compliance of emergency shutdown logic for chemical injection pump
ValidationWorkflow StepVerify SIL compliance of emergency shutdown logic for chemical injection pump
CalculationWorkflow StepAssess interlock consistency across control system layers (DCS, PLC, local panel)
CalculationWorkflow StepSize backup power duration for critical control system during 15-minute utility outage
CalculationWorkflow StepSize backup power duration for critical control system during 15-minute utility outage
ValidationWorkflow StepSize backup power duration for critical control system during 15-minute utility outage
CalculationWorkflow StepValidate sensor fault simulation coverage for HAZOP-identified loss-of-flow scenario
CalculationWorkflow StepValidate sensor fault simulation coverage for HAZOP-identified loss-of-flow scenario