Purpose

The ESD dynamic testing workflow turns an emergency shutdown philosophy, cause-and-effect row, technical documentation, and optional tagreader event data into a repeatable NeqSim simulation test. It is intended for virtual commissioning, proof-test planning, tagreader replay, and evidence packs for NORSOK S-001 Clause 11 reviews.

The workflow does not replace certified SIS/FAT/SAT or proof testing on the real safety system. It checks whether the documented ESD sequence, when represented in NeqSim, gives the expected process response.

Package Structure

Core classes are in neqsim.process.safety.esd:

Class Role
EmergencyShutdownTestPlan Test setup: duration, trigger time, logic names, tag map, field data, references, and criteria
EmergencyShutdownTestCriterion Acceptance checks for final values, min/max values, response changes, logic completion, simulation errors, and model-to-field deviation
EmergencyShutdownTestRunner Executes existing ProcessLogic sequences with ProcessSystem.runTransient(...) and captures monitored values
EmergencyShutdownTestResult JSON-ready evidence report with verdict, time series, signal statistics, field comparisons, warnings, errors, and criteria results

The package reuses existing NeqSim functionality rather than duplicating it:

Existing API Used For
ESDValve Fail-safe isolation valve dynamics and stroke time
ESDLogic and LogicAction Cause-and-effect shutdown sequence execution
ProcessSystem.runTransient(...) Dynamic process simulation
OperationalTagMap Mapping logical tags to historian tags, P&ID references, and NeqSim automation addresses
ProcessAutomation Reading monitored variables such as valve opening, pressure, temperature, and flow

Workflow

  1. Extract ESD functions from technical documentation such as C&E, SRS, P&IDs, valve datasheets, F&G action charts, and operating procedures.
  2. Create NeqSim equipment and ESD logic using existing process and safety classes.
  3. Create an OperationalTagMap that maps public logical tags to private historian tags and NeqSim automation addresses.
  4. Load tagreader event data into a Map<String, Double> keyed by logical tag or historian tag.
  5. Build an EmergencyShutdownTestPlan with monitor tags, criteria, evidence references, and standards references.
  6. Run EmergencyShutdownTestRunner.run(...) and store EmergencyShutdownTestResult.toJson() in the task evidence package or report.

Example

ESDLogic esdLogic = new ESDLogic("ESD Level 1");
esdLogic.addAction(new TripValveAction(isolationValve), 0.0);

OperationalTagMap tagMap = new OperationalTagMap()
    .addBinding(OperationalTagBinding.builder("xv_opening")
        .historianTag("PRIVATE-XV-001-ZSO")
        .pidReference("P&ID-ESD-001/XV-001")
        .automationAddress("ESD Inlet Isolation.percentValveOpening")
        .unit("%")
        .role(InstrumentTagRole.BENCHMARK)
        .build());

EmergencyShutdownTestPlan plan = EmergencyShutdownTestPlan.builder("ESD1 isolation closure")
    .duration(8.0)
    .timeStep(1.0)
    .tagMap(tagMap)
    .enableLogic("ESD Level 1")
    .triggerLogic("ESD Level 1")
    .fieldData("xv_opening", 0.0)
    .criterion(EmergencyShutdownTestCriterion.finalAtMost(
        "ESD-XV-CLOSED", "xv_opening", 5.0, "%")
        .withClause("NORSOK S-001 Clause 11"))
    .criterion(EmergencyShutdownTestCriterion.logicCompleted(
        "ESD-LOGIC-COMPLETE", "ESD Level 1"))
    .criterion(EmergencyShutdownTestCriterion.fieldAbsoluteDeviationAtMost(
        "ESD-FIELD-MATCH", "xv_opening", 5.0, "%"))
    .standardReference("NORSOK S-001 Clause 11 emergency shutdown testing")
    .evidenceReference("Cause and effect matrix row ESD-001")
    .build();

EmergencyShutdownTestResult report = EmergencyShutdownTestRunner.run(process, plan, esdLogic);
String json = report.toJson();

The example pattern is covered by the focused EmergencyShutdownTestRunnerTest unit test.

Evidence Output

The JSON report includes:

Field Description
verdict PASS, PASS_WITH_WARNINGS, or FAIL
signalStats Initial, final, minimum, and maximum values for every monitored logical tag
timeSeries Time-stamped monitored values for replay and plotting
logicStates Final state of each supplied ProcessLogic sequence
fieldComparisons Model-to-field deviation for tagreader-backed evidence
criterionResults Requirement-level pass/fail result with clause, severity, and recommendation
evidenceReferences Source documents such as C&E, SRS, P&ID, valve datasheets, and procedure IDs