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Sustaining an Alarm Management Strategy

with ABB’s System with ABB’s System 800xA800xA

Presented by Roy TannerSystem 800xA Marketing Manager

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Facts about ABB

Headquarters: Zurich, Switzerland

About 104,000 employees in around 100 countries

Orders in 2005: $23.6 billion

Revenues in 2005: $22.4 billion

Research and Development in 2005: $960 million

Listed on Stockholm, Swiss & New York exchanges; traded on virt-x

A leading power and automation technology company with strong market positions in its core businesses

Core business organized into 5 divisions; Power Products, Power Systems, Automation Products, Process Automation, and Robotics

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Divisional Structure and Portfolio

Robots, peripheral devices and modular manufacturing solutions for industry

Process Automation

Sales: $5.0 billion

Control systems and application-specific automation solutions for process industries

Substations, FACTS, HVDC, HVDC Light, power plant & network automation

Power Systems

Sales: $4.0 billion

Robotics

Sales: $1.7 billion

Transformers, high- and medium-voltage switchgear, breakers,automation relays

Power Products

Sales: $6.4 billion

Automation Products

Sales: $5.9 billion

Low-voltage products, drives, motors, power electronics, and instrumentation

* Estimated 2005 revenues, Including internal sales to other divisions

Market-leading positions in most key product areas Integrated solutions for grid reliability, productivity and energy efficiency Robust global value chain to serve established and emerging markets Extensive global network of value-added channel partners

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Reduces time from decision to action

Optimizes plant asset availability and performance

Integrates information for improved visibility

Improves batch consistency, quality, and cycle time

Uses proven solutions based on industry knowledge and experience

Extends installed system capabilities through seamless evolution

System 800xA Extended Automation

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Traditional Automation

Instrumentation& Drives

“Traditional” DCS/OCS

InformationManagement

Asset Optimization

S88 ProductionManagement

ProgrammableLogic Control

Advanced Control

Motor ControlCenters

Safety

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System 800xA

A single operations, engineering and information management environment for

an Extended Automation scope

Redefining the Automation System Standard

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Industrial IT Technology Partnership

Reduced Total Cost of OwnershipReduced Total Cost of Ownership

Increased Production OutputIncreased Production Output

Improved SafetyImproved Safety

Industrial IT solutions build upon the 800xA extended automation system with integrated devices and 3rd party software applications to deliver Continuous Improvement for our customers.

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Many products in each category are currently Certified as Industrial IT Enabled against System 800xA.

Industrial IT Technology PartnershipIndustrial IT solutions leverage best-in-class products from ABB and partners to deliver value in every solution area.

Infrastructure components Hirschmann switches Cisco switches MOXA switches OnTime switches Phoenix switches Dell PC / Server HP PC / Server IBM PC / Server IBM Blade Server

Hardware TDC3000 Connect SafeGuard Connect PlantGuard Connect ABB INSUM Metso Valve Positioner IIT Training Simulation Stratus FT Servers

Software800xA Integrated functions

Merriam Device MgmtSystem (Calibration) Real Time ProductionIntelligence (OEE) MRO Maximo CMMS SAP/PM CMMS IFS CMMS AES SmartPlant (InTools) Matrikon ProcessGuard

Intelligent Devices All devices in the device

integration library >20 HART types >20 FF types >12 Profibus types

ABB and other vendors Fisher Rosemount Samson Westlock Flowserve Siemens

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What is alarm management?

It is not a product…

“Work process by which alarms are engineered, monitored, and managed to ensure safe, reliable operations”

Spans multiple departments, requires everyone’s buy in, and part of everyday operational practices

C/O Matrikon Inc.

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How Are These Objectives Achieved?

Alarm Philosophy

Benchmark &Assessment

Alarm Rationalization

Implementation &Execution

ContinuousImprovement

Maintenance

C/O Matrikon Inc.

By following a proven process

By using best in class technology to match project requirements

By using standards and good practice guides

Sustaining an alarm management program often presents the biggest challenge

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Sustaining the Strategy

C/O Matrikon Inc.

Alarm Loading / Plant Reliability Indicator

Bad Actors

RationalizationWith Alarm Hiding

Can degrade over time

Typical results with DCSsMaximum # Alarms per Hr

Ave

rage

# A

larm

s pe

r H

r

600060060

600

60

6 X

Impossible

Overloaded

Reactive

StableRobust

PredictiveBad ActorsNuisance Alarms

Alarm RationalizationDynamic Alarm

Handling

Degradation over Time

The ABB-Matrikon partnership is focused on ensuring results are easily sustained!

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Continuous Improvement Challenges

EEMUA #191 & ISA RP18.2 outline best practices

Alarm management involves all departments, how can you ensure this is an on-going priority for everyone?

Operations

“ No tools to verify key problems and then take action” “ I don’t want another screen to look at.”

Engineering “I follow good change management processes, but I don’t know if the

current DCS matches engineered values” “I need real-time access to CURRENT information on DCS inhibited

alarms to verify and approve” Maintenance / DCS Technicians

“Too much to do already! Are these work orders valid/important?” “I want a system that is easy to maintain and administer”

Management “I am losing experienced operators, how can we leverage their

experience?”

Personnel are overworked. In order to sustain an alarm strategy, we need

to streamline the process!

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System 800xA and ProcessGuard

ABB System 800xA- Extended Automation system

built for continuous improvement and risk reduction

- Built with Industrial IT technology that consolidates and filters information

- IIT Technology Partnership program to connect and utilize best in class offerings

Matrikon’s methodology & technology combined with ABB’s 800xA Real-Time Alarm Technology is the first complete alarm management solution!

Matrikon AlarmMOCCA

- Alarm management of change configuration assistant

- Provides a safe environment through improving change management practices

- Stores parameters, change logs, difference reporting from actual DCS values

- Contains alarm definitions, cause, effect, and recommended action information which can assist operations

Matrikon Process Guard

- Comprehensive alarm and event analysis package that simplifies the benchmarking process

- Provides a consistent alarm management program throughout the entire lifecycle and enterprise

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Industrial IT VisionIndustrial IT is ABB’s commitment to open interconnectivity of Automation and Power solutions and services, leveraging the ABB portfolio, 3rd party products and the relevant standards.

Industrial IT enables ABB to provide three core values to our customers: Reduced Total Cost of Ownership (TCO)

Increase Production Output

Reduced Risk and Improved Safety

Industrial IT technology enables interoperability of applications: Direct access to information

Template based connectivity

Single window operator environment

ABB System 800xA

Matrikon ProcessGuard

AE Messages viaPrinter port (Serial)

Printer port (TCP/IP)OPC AE (SV 5)

Text File (Report)ODBC (Info Mgt)

Matrikon Matrikon AlarmInsight AlarmInsight for System 800xAfor System 800xA

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Matrikon AlarmInsight Provides a complete alarm management solution …by providing

a certified, pre-tested, integrated system components

Matrikon AlarmInsight Aspect System Direct, contextual access to ProcessGuard

Alarm Analysis and AlarmMOCCA reports to streamline workflows

Direct access to Operator Assistance report giving cause, effect, and recommended action data for operations consistency and decision support.

Easy to implement (no programming needed) to reduce engineering and reduce maintenance.

AECollector able to be loaded on System800xA clients to reduce time to commission.

Combined desktop tools to improve root cause analysis (offered as a service from Matrikon)

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Functional Structure – AI Report Aspect

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Operator view – AI Report Aspect

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Summary

Alarm Management is more than a product

System 800xA has features that help implement and maintain an alarm management strategy such as Alarm Hiding and effective navigation, organization and presentation.

Matrikon’s ProcessGuard has features that

Industrial IT Enabled Matrikon AlarmInsight helps sustain an alarm management strategy