10 Situational Awareness

7/31/2019 10 Situational Awareness

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2010 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services ofInvensys are proprietary marks of Invensys or its subsidiaries. All third party t rademarks and service marks arethe proprietary marks of their respective owners.

Invensys 00/00/00 Invensys proprietary & confidentialSlide 2

Situational Awareness

SME

Rob Kambach


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1Alarm Management

State off Business.

Slide 3


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Current state around alarming.Configured alarms per operator: Number of Alarms a operator

Can theoretically respond to:

So that means in systems overall as of today operators get overwhelmed with alarms and messages.

Affecting several crucial areas of plant operations:- Reducing the operational effectives.- Economical impact: Unnecessary plant shut downs.( in the USA alone this costs $20 Billion a year)- Poor alarm management causes also Loss in product quality, danger to Humans and environment and orImage loss of a respective company.


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Why did alarms increase?Automation brought enhancements to systems and visibility to control rooms,on the downside it added complexity.

So a sensor that 10 years ago was brought in by 4-20mA isNow a intelligent field device.A device that reports back alarm states, condition and configuration, in essencethe alarm model has changed and we did not change we still have the same alarm,sub systems as 10 years ago.

Another part is that systems even when they are traditionally wired by defaultgenerate more data.

So for example a valve will not only have open close it will also report its state back.

A motor in the olden days had start / stop now it has a frequency drive thatGives back Start, Stop, Speed feedback, set point, alarm state.

So a motor had two signals now it has 5, multiply these scenarios over hundreds ofAssets and you get thousands of possible alarms and states back into the system.Compared with hundreds 10 years ago

So this also requires on our side a different approach to alarm handling givingMore ways and options to rationalize all this data even before it gets to the operator.

Where are we today?


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What are the maximums on Alarms aOperator respond properly two?

Slide 6

Alarm Performance Metrics per Controller PositionBased upon at least 30 days of data

Metric Target Value

Annunciated Alarms per Time:Target Value: Very Likelyto be Acceptable

Target Value: MaximumManageable

Annunciated Alarms Per Day per Controller Position ~150 alarms per day ~300 alarms per day

Annunciated Alarms Per Hour per Controller Position ~6 (average) ~12 (average)

Annunciated Alarms Per 10 Minutes per Controller Position ~1 (average) ~2 (average)Metric Target Value

Percentage of hours containing > 30 alarms ~ 5 alarms ~


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What happens when we dont react toabnormal situations?

Slide 7

A single plant shutdown resulting from an abnormal situation not detected byoperating personal can wipe out instantly all the benefits achieved throughoptimization and APC.

According to studies 20$ Billionin the USA is lost on an annualbasis in production because of

abnormal situations.


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RFQs incorporate more oftenmandatory standards and guidelines:

EEMUA 191, Alarm systems a guide to design.

Namur NA 102 Worksheet, Alarm Management.

NPD YA 711, Principles for alarm design (Norwegian petroleum

doctorate slowly adopted throughout Europe as the standard)

VDI/VDE Guideline 3699 (process control using monitors)

ISA s18.02, Management of alarm systems for the process industry.

Standards.

ANSI/ISA18.2

Management of AlarmSystemsfor the

ProcessIndustries

API RP-1167Alarm

ManagementFor Pipeline

Systems
http://www.api.org/


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Market positioning systems.

Complexity

I/O Count10 100 1K 10K 100K 1M

HMI SCADA MarketIndusoft, Iconics, InTouchOEM panels, Skids, Stand alonemachines, Discrete Manufacturing.

Hybrid DCSSystem Platform,Eurotherm Esuite, Delta V, ABB 800XA, PCS 7, Controllogix PlantPaxWater, waste water, chemical, batch, Pharmaceutical,food and beverage.

DCS Market

Foxboro I/A, Honeywell experion, OvationPower, Refinerys, Nuclear, LNG

Basic Alarm

management


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The difference between basic andAdvanced Alarm Management

Slide 10

Basic AlarmManagement

Advanced AlarmManagement

Alarm Shelving Integration withprocedures andworkflow

Alarm Folding Analytics and patternrecognition

Alarm Inhibit Statistics and reports

Alarm Masking Semantic modeling andcontextualizing

Alarm HistorisationAlarm Queries

Runtime 100% Historical 80% Runtime20%


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Competition Capabilities (Min compliance)

Invensys 5/12/2011Invensys proprietary &confidential

11

Competition Alarm Type Compliance Notes

Honeywell Basic

Advanced

Yes

Yes (In house)

Abnormal Situation Management (ASM)

founder and worked closely with Shell to

ensure safe production (ESP).

Yokogawa Basic

Advanced

Yes

Yes (In House)

Working closely to meet ESP requirements &

ARAMCO standards, plus Shells condition

based operations (CBO)

Emerson Basic

Advanced

Yes

Partial (In House)

Yes based on feedback from BP Upstream

requirements, otherwise suspect.

ABB Basic

Advanced

Yes

Partial (Matrikon)

Yes based on feedback from Statoil. Have

embedded Matrikon software who provide

some multivariate analysis, otherwise suspect.

SIEMENS Basic

Advanced

Yes

Partial

Yes based on feedback from Statoil and BASF

requirements, otherwise suspect


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Current Solution

Slide 12Slide 12

3rd Party Application

Alarm Provider

InTouch AlarmProvider Toolkit

InTouch AlarmDatabaseAlarm Logger

Clients

Application Server

AppObject

InTouch

Area object

Alarm Provider

Alarm Provider

InFusion

IA Alarm Provider

InTouchAlarmManager Pas Alarm

Management Basicand Advanced

UREASON Alarm

Management Basic andAdvanced


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Roadmap Alarm Program:

Slide 13

Phase 0 (today)

Best PracticesaroundSituationalawareness

Phase 1OpsManage 2012

Basic AlarmManagement

Phase 2LongTerm Scalability,

Performance andinteroperability

Phase 3 Future

Connectivity andcontextualization


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Phase 1 deliverables

User Defined Alarm records for AppServer

Event priority changeable

Suppression of duplicate messages.

Alarm Shelving, the ability to shelve alarms based on a definable maximum time ifproper authentication is met.

Alarm Grouping the ability to group alarms that are related so collapse them into onemessage.

Quickly be able to navigate from the Alarm to the graphic the alarm originates from.

Redundancy improvements Alarm Logger.

UI client based on new requirements.

Alarm Masking the ability to dynamicly supress Areas by production state of the diffrentAreas.

Support of a new alarmtype on Field Attributes, Bit Pattern.

Slide 14


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2Phase 0 Best Practices

Situational awareness (PAS)

Slide 15

API RP-1167Alarm

ManagementFor Pipeline

Systems
http://www.api.org/


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A quick google for HMI Screens.

Slide 16

Lots of colors and pretty pictures


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Setting priorities properly

Have only 4 to 5 priorities in the Alarm Sub System.

Have very View Priority 1 Alarms these should be only for very critical

or safety related.

Events are not Alarms so they should not show in a Alarm view and

have Priority 5 or 4.

The system shall only represent four active alarm priorities:

Priority 1 Critical (only Safety and Emergency related)

Priority 2 High

Priority 3 Medium

Priority 4 Low

Priority 5 Events and logging only no Alarms.

Slide 17

Ranking and economical scale:


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Tie a value to the priorities before youclassify Alarms:

Slide 18

Ranking and economical scale:

Operational risk of the Alarms.


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Colors and markings of AlarmsChoose colors of alarms shall not be used in any process graphic or state

representation make sure they can be read by people that are color blind

most important these should be the brightest colors in the system.

Slide 19

RGB WWL WWH Ex.

Priority 1: RedCritical, Safety or Emergency related

255,

0,

750 999

Priority 2: Yellow

High Priority

255,

255,0

500 749

Priority 3: Margenta

Medium Priority

213,

43,213

250 499

Priority 4: Dim cyan Low Priority

99,231,

231

2 249

Priority 5:Events and logging

185,116,104

1 1


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Represent these same colors in theAlarm grid on a neutral background

Slide 20

Addional colors:

Blocked / suppressed / hidden / shelved

Blue colour is used to indicate that an instrument or

equipment is in a mode where safety, control and alarming

functions are disabled.

RGB

0,

0,

255

Ack or Unck Return to Normal

Grey background colour is used to indicate the alarm

returned to normal condition

RGB

153,

153,

153


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Resulting in Alarm grids that are easyto read and point out priorities

Slide 21

Flash On

Flash Off

Standard Configuration


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Display Design..

How can I do things different then today with what I have.?

Slide 22


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A quick Reminder

Level_1 Plant Overview Graphic, Typical on Large Screens

Level_2 Production Line or Plant Section Graphic. Most important

controls visible and usable.

Level_3 Process Cell or Unit Graphic. All process control shall be

possible from these pages.

Level_4 Loop, Motor, Pump, Valve Faceplates Etc. or Axillary pages.

Slide 23


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High Performance HMI Benefits

Study by Nova Chemicals and ASM Consortium

Task Improvement

Detecting AbnormalSituations BeforeAlarms Occur

A 5Xincrease

Success Rate in

Handling AbnormalSituation

37% overbase case

Time to CompleteAbnormal SituationTasks

41%reduction

$800,000 peryear savingsanticipated on

1 ethyleneplant

Time after time, poor HMIs are cited as

contributing factors to major accidents

D t i N t I f ti I Fl ff Si k?


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Data is Not Information: Is Fluffy Sick?

Blood Tests for Fluffy -1

Test Results

HCT 31.7%

HGB 10.2 g/dl

MCHC 32.2 6/dl

WBC 9.2 x109 /L

GRANS 6.5 x109 /L

L/M 2.7 x109 /L

PLT 310 x109 /L

Answer: Unless you are

vet, how can you know?


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How About Now?

ABNORMAL VALUES can be seen at a glance.

Blood Tests for Fluffy -3

Test Results Range IndicatorLow Normal - High

HCT 31.7% 24.0 45.0

HGB 10.2 g/dl 8.0 15.0

MCHC 32.2 6/dl 30.0 - 36.9

WBC 9.2 x109 /L 5.0 18.9

GRANS 6.5 x109 /L 2.5 12.5

L/M 2.7 x109

/L 1.5 7.8

PLT 310 x109 /L 175 - 500


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Data is Not Information:

45.1

48.2

50.6

53.854.9

22.5%

42.9

98.2 MPPH

221.2 PSI

96.2% XYZ

22.3% ABC

60.1

DP INH2012-15 22.8

1-12 16.31-15 39.1

77.8 MPPH

45.1

48.2

50.6

53.854.9

22.5%

42.9

98.2 MPPH

221.2 PSI

96.2% XYZ

22.3% ABC

60.1

DP INH2012-15 22.8

1-12 16.31-15 39.1

77.8 MPPHLots of Data but

Not Much Information!

Poor Presentation

High Mental Workload

to Decipher

West East

Drive: 232.2 amps

Cooler

W. Vibration: 2.77 E. Vibration: 3.07

2.77

MSCFH

155.2

F 108.2

F 166.1

F55.7 psig

135.1

psig

190.5 psig

Oil 155.2 FOil 85.1 psi

65.1 F

P&IDs are NOT HMIs!

Sh INFORMATION DATA


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Show INFORMATION not DATA

Cool

gpm

RECYCLE COMPRESSOR K43

Alarm IndicatorAppears herewith PriorityLevel andColor

DesirableOperatingRange shownas pale bluearea

Alarm Rangedepicted and(for some)shutdownvalue

Alarm Rangedepicted and(for some)interlockvalueShow Values Show Trends

Buttons for additionalfunctionality

2

Compressor Status Showing Alarm/Shutdown Limits

Suct

psig

Inter

psig

Dsch

psig

Suct

degF

Inter

degF

Dsch

degF

E. Vib

mil

N. Vib

mil

W. Vib

mil

Motor

Amps

Oil

psig

Oil

degF

42.7

38.793.1

18595 120

170

128

9170

80

290

Operational statusis obvious at a

single glance!

Analog is powerful!


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Analog is powerful!

A Column Temperature Profile

Deviation orabsolute numbersoptionally toggled

20.1

24.2

25.6

27.8

28.9

+1.1

-0.7

+0.8

A goodprofile?

Yes, thisone is.

Too hot atthe top, toocold at thebottom

Optional:Line colorindicatesabnormality,

alarm is notyet activated


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Example of a poor Level 3 Display

Slide 30


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A Better Level_3 Display running Normal

Slide 31


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Same Level 3 with Alarms.

Slide 32


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Level 3 view High Performance HMI of


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Level 3 view High Performance HMI ofthe Reactor.

Slide 34

PSOAUTO

76.8 MPH76.088.5 %

Main Feed

Main Feed MPH

72.0

80.0

-60 -30-90 2 Hours

PSOAUTO

11.9 MPH12.022.3 %

Additive 1

Additive 1 MPH

10.0

14.0

-60 -30-90 2Hours

PSO

AUTO

4.0 MPH4.0

44.3 %

Additive 2

Additive 2 MPH

2.0

6.0

-60 -30-90 2 Hours

VENT SYS

Analysis: Purity %

32.0

40.0

-60 -30-90 2 Hours

Analysis: Inhibitor Concentration %

4.0

6.0

-60 -30-90 2 Hours

AgitatorON

Reactor M5

Pump 1RUNNING

PSOAUTO

95.044.3 %

M5 Pressure98.0 psig

PSOAUTO

70.054.3 %

M5 Level %71.0 %

ThioniteProduct: Mid-Run

52.3 %

5.0 %

CoolantFlow

CoolantTemp

PSOAUTO

45.054.3 %

M5 Temp45.0 C

To

Coils

COOLING SYS

92.0 MPHPRODUCT

Temperature C

40.0

48.0

-60 -30-90 2 Hours

Diagnostics1-OK

PumpsNeeded 1

SHUTDOWN

M5

Run Plan:Actual:

FREEZEM5

IN

Reset

OUT

Calc Diff:

-10%

+10%

Hours: 238.1Since:

State:

19707 19301

Material Balance

2.1 %

06/02/0714:00:00

ISOLATEM5

Pump 2STOPPED2-BAD

M4Main

Menu

- Level 3 -M5

Interlocks

Feed

System

Product

Recovery

Level 1ReactionOverview

M5SequenceOverlay

PurgeRate

ConversionEfficiency

Cat.Activity

ReserveCapacity

M5StartupOverlay

M6- Level 3 -

M5 Cooling

System

Feed Components: A - B - C

+/- 5 psi, 2hr

+/- 1 %, 2hr

Trend

Control

4

7 Steps for Creating High Performance Displays


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7 Steps for Creating High Performance Displays

Step 1: Develop a High Performance HMI Philosophy and Style Guide

Step 2: Assess and benchmark existing graphics against the HMI

Philosophy

Step 3: Determine specific performance and goal objectives for the

control of the process, for all modes of operation

Step 4: Perform task analysis to determine the control manipulations

needed to achieve the performance and goal objectives

Step 5: Design and build high performance graphics, using the design

principles in the HMI Philosophy and elements from the Style

Guide, to address the identified tasks

Step 6: Install, commission, and provide training on the new HMI

Step 7: Control, maintain, and periodically reassess the HMI performance


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Key points to take home:

Alarms should be a integral part of the design of a system a thought upfront and not an after thought.

During the design a important consideration should be how can I

effectively represent an abnormal situation.

How can I quickly guide the operator to the source of the Alarm.

Alarm states should be an integral part of the design of the process

graphics.

Slide 36


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3Roadmap High

Performance HMI

Slide 37


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High Performance HMI Roadmap

Delivery of ArchestrA high performance HMI symbol library:

OpsManage 2012

Slide 38


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1Introduction

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10 Situational Awareness

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