Mark Bitto / ABB Inc / PSPG / CIBO Technical Focus Group ...

Instrumented and Actuated SystemsImproving Operator Effectiveness

Mark Bitto / ABB Inc / PSPG / CIBO Technical Focus Group / June 2015

Improving operator effectivenessAbout the speaker

© ABB Inc.June 3, 2015 | Slide 2

Speaker name: Mark Bitto

Speaker title: Global Products Marketing ManagerProduct Group Automation ProductsBU Power Generation

Company name: ABB Inc.

Location: Wickliffe, OH, USA

Contact: [email protected]/symphonyplus

mailto:[email protected]

http://new.abb.com/power-generation/symphony-plus

Improving operator effectivenessIndustry trends

Generational shift in workforce

Seasoned operators retiring

Fewer, inexperienced operators entering

Consolidation of operations

Explosion of data collection

Adoption of standards

Regulation compliance


Improving operator effectivenessWhy focus on the operator?

Estimated that abnormal situations account for more than $20 billion USD lost in the US economy alone

ARC estimates that almost 80 percent of these losses are preventable and 42 percent are primarily the result of operator error

Safety incidents often attributed to operator error due to poor decision making caused by the lack of information, such as procedures, and training. (www.csb.gov)

Source: ARC Advisory Group

People

42%

Process22%

Equipment36%



Improving operator effectivenessWhere’s the focus?

Traditional control room environments:

Complex environment with a multitude of different systems

Geographically distributed operations (remote / unmanned)

Typically no overview information to give the bigger picture

Low level of situation awareness

Poorly integrated CCTV and telecom equipment

Too many keyboards and other input devices

Non-ergonomic operator desks with built-in computers that generate heat, noise and are difficult to keep clean

Unpleasant environment, with little consideration to human factors, lighting, noise, etc.

http://www.google.com/url?sa=i&rct=j&q=boiler+room+operator+control+rooms&source=images&cd=&cad=rja&docid=U0FhXisJ_oPmlM&tbnid=fgRr3zNx-RresM:&ved=0CAUQjRw&url=http://nwscc.edu/nsf/danielmcreport.html&ei=ZNt_UaGhIceROKPhgPAE&bvm=bv.45921128,d.Yms&psig=AFQjCNES2WCKCUJw1CH0ghBX4U7yjd-2OA&ust=1367419926963569



Improving operator effectiveness Where do we start?

Organizational structure, roles and responsibilities

Operator Interface Design

Alarm Management

ConditionMonitoring

Asset Utilization

Workplace design

Procedures / Workflow

Control Room Design

and Ergonomics

Operator competence, training and skills development

KnowledgeManagement Process and abnormal

situation understanding

Alertness and Fatigue

Safety Critical

Communications




Improving operator effectiveness The four pillars of operator effectiveness

Maximum Operator

Effectiveness

Operator competency

Human factor ergonomics

Plant system integration

High performance

HMI

Integrated control room design

User specific workplaces

Asset management & CMMS integration

Integrated history & 3rd party systems

Plant performance optimization

Simulation solutions

Plant improvement program platform

Operator training

High performance graphics

Integrated alarm management

High performance navigations


Improving operator effectivenessRemoving the isolated islands of control

Improving operator effectiveness1) Integrated process

view


Improving operator effectivenessRemoving the isolated islands of control


view

Benefits:

• Enables centralized, consolidated operations

• Gives you one single point for vertical integration

• Seamless data presentation from varied sources, one consistent and familiar operator environment regardless of underlying control system

• Consolidated alarm and event lists simplify troubleshooting


Improving operator effectivenessCentralized, consolidated and consistent operations


view2) Consolidated,

consistent operations environment

Alarm Group / Graphic Bars

Icon Bar Navigation

Tab / Tile Windows

GreyscaleNormal Operation

Display Select

Tag BrowserFast Search

Operator NotesPoints off scan

Operator NotesAlarm and Event List

Operating ParametersRed Tag

Side MenuFlyout Navigation


Improving operator effectivenessContextual navigation




3) Contextual access


Improving operator effectivenessUser specific workplaces




3) Contextual access

EngineeringManagement

OperationsMaintenance


Improving operator effectivenessInform with context to drive effective actions

Operator interface design should promote the most efficient way to detect and correct abnormal situations

High Performance is more than just grey-scale displays

It is a state of the art methodology that promotes abnormal situation awareness and operator response




3) Contextual access4) High performance

graphics


Improving operator effectivenessInform with context to drive effective actions

Examples of abnormal situational awareness display hierarchy

• Overview Surveillance (top right)

• Process Surveillance (right)

• System, Sub-system Detail (below)

• Diagnostic Detail (below left)





graphics


Improving operator effectivenessAdvanced alarm handling and analysis





graphics5) Integrated alarm

management

Source: Matrikon

Poor alarm management leads to operator ambivalence

Operators totally ignore the alarm horn and "run on instinct"

Operators have cut the wires to the alarm horn because it “went off too often”

High rates of “false” alarms influence the perception of “real” alarms

Overload of operator short term memory

EEMUA O&G PetroChem Power Other

Average alarms per day 144 1200 1500 2000 900

Average standing alarms 9 50 100 65 35

Peak alarms per 10 minutes 10 220 180 350 180

Average alarms / 10 minute interval 1 6 9 8 5

Distribution % (Low / Med / High) 80 / 15 /5 25 / 40 / 35 25 / 40 / 35 25 / 40 / 35 25 / 40 / 35








management

ISA 18.2 / EEMUA 191 alarm management life cycle

Next Generation HMI ISA 18.2 / EEMUA 191-compliant alarm analysis tools help users categorize occurring alarms, while the integrated alarm management system keeps operators focused.

User defined filters

Alarm and event frequency

Priority distribution

Alarm performance levels

HMI integrated alarm analysis tools








management

Next Generation HMI ISA 18.2 / EEMUA 191-compliant alarm analysis tools help users categorize occurring alarms, while the integrated alarm management system keeps operators focused.

x

User defined filters

Alarm and event frequency

Priority distribution

Alarm performance levels

Advanced alarm analysis tools Instantaneous reports Alarm / Event frequency Alarms over time Priority distribution Alarm duration Time to acknowledge Alarm performance Loops in manual Operator actions Exceeding threshold Standing alarms Co-occurences

Alarm presentation features Alarm grouping Alarm filtering Alarm inhibiting Alarm shelving Alarm suppressing


Improving operator effectivenessAsset management and optimization






management6) Integrated asset

management

Wealth of plant data used to identify and alert on degrading asset performance before failure occurs

All asset levels: field devices, process / electrical / environmental equipment, control loops, power supplies, communication and network equipment, etc.

Moves maintenance from corrective maintenance program to proactive or predictive maintenance program


Improving operator effectivenessIntegrated operations and maintenance







management7) Streamlined work

processesPlant – normal state

High Performance HMI alarm notification

SMS alarm notification+

Call acknowledgement

Proactive response Engineering

Operations

Management

Plant – alarm state

Maintenance

SMS notification:

• Allows for easy alarm notification with remote users

• Quick resolution of maintenance issues before failure


Improving operator effectivenessIntegrated operations and maintenance








processes

Plant – normal state

High Performance HMI alarm notification

Proactive response

Plant – alarm state

Seamless interaction between plant HMI and CMMS

View current CMMS schedules directly from HMI

If not scheduled, create and submit CMMS work order report from HMI

CMMS integration:

Allows for easy communication with and navigation to asset-specific maintenance activities

Quick resolution of maintenance issues before failure


Improving operator effectivenessEmbedded security features








processes8) Inherent security

Built in cyber security for software, systems and devices User Authentication Role Based Access Control Event Logging / Audit Trails Backup / Restore Hardened Hosts Host Firewall Configuration Antivirus Network Zones Etc.


Improving operator effectivenessOperator competency








processes8) Inherent security9) Operator training

simulators

Operator training simulation provides training of personnel to familiarize operator with their actual work environment

Includes trainer station to set initial conditions, review performance / playback, tied to models of plant equipment

Additional benefits include reduce time to commission and provides testing environment


Improving operator effectivenessAttention to human factors









simulators10) Integrated control

room design

Human factors and ergonomics is concerned with the "fit" between the user, equipment and their environments.

Reducing stress and fatigue

Increases performance and alertness

Reduced health issues and turnovers

Operator environment can help retain

existing resources and attract new

talent


Improving operator effectivenessErgonomic control room design










room design

Personalized ergonomics

Collaboration platform

Cockpit solution

Comply with today’s and future Human Factor requirements


Improving operator effectiveness Summary

Improving the operator’s visibility to plant performance while filtering out the “noise” will lead operators to greater

awareness, faster response, and better decisions




Improving operator effectivenessSummary: Case examples










room design

Source: the High Performance HMI Handbook by Bill Hollifield, Dana Oliverr, Ian Nimmo, and Eddie Habibi : quoting studies done by ASM – Abnormal Situation Management

TaskWith

traditional HMI

With high

performance HMIResult

Detecting abnormal situations before alarms occur

10% of the time 48% of the time 5x increase

Success rate in handling abnormal situations

70% 96% 26% over base

case

Time to complete abnormal situation tasks 18.1 min 10.6 min 41% reduction


Improving operator effectivenessSummary: For your consideration










room design

Large financial impact for small improvements in: Availability, Performance, Quality

US Paper AverageTotal Time

8,760 8,760 Theoretical Prod/Year Actual Prod/Year

179,907 145,581 179,907 150,320

Production Rate (T/Hr)

Contribution

Margin/Year

20.54 OEE 45,857,487 20.54 80.9% 47,350,456 Profit

83.6% 9,384,033 Contribution Margin/Unit 10,805,573

Availability 315.0089.8% 315.0090.8%

Direct Maintenance Fixed Costs/year Revenues Profitability Delta (Annual)

Performance Price/Unit Pct Change 9,193,125 36,473,454 101,906,406 9.21% 1.06%93.0% $700.00 0 9,193,125 36,544,883 105,224,142 10.27% 1,421,540$ 94.0% $700.00

Depretiation Fixed Assets Profit ROCE

Quality Yield Variable Cost/Unit 4,000,000 200,000,000 9,384,033 4.56% 0.69%97.0% $385.00 4,071,429 200,000,000 10,805,573 5.25%98.0% $385.00

Labor & Other fixed costs NOWC Capital Employed

Pct Change 23,280,330 6,000,000 206,000,000 0 23,280,330 6,000,000 206,000,000

7,089

0%10%20%30%40%50%60%70%80%90%

100%

1

Baseline

Quality

Performance

Availability

NetProduction 7,319

0%

20%

40%

60%

80%

100%

1

WITH IMPROVEMENTS

Quality

Performance

Availability

Net Production

ROCE

Profitability

OEEMaintenance Cost

Revenues

4.20%

4.40%

4.60%

4.80%

5.00%

5.20%

5.40%

1 2

Financial Impact:

Profitability &

Return on Capital

Employed (ROCE)Availability

Performance

Quality ROA = Income / Assets


Improving operator effectivenessSummary: For your consideration










room design

Large financial impact for small improvements in: Availability, Performance, Quality

US Paper AverageTotal Time

8,760 8,760 Theoretical Prod/Year Actual Prod/Year

179,907 145,581 179,907 150,320

Production Rate (T/Hr)

Contribution

Margin/Year

20.54 OEE 45,857,487 20.54 80.9% 47,350,456 Profit

83.6% 9,384,033 Contribution Margin/Unit 10,805,573

Availability 315.0089.8% 315.0090.8%

Direct Maintenance Fixed Costs/year Revenues Profitability Delta (Annual)

Performance Price/Unit Pct Change 9,193,125 36,473,454 101,906,406 9.21% 1.06%93.0% $700.00 0 9,193,125 36,544,883 105,224,142 10.27% 1,421,540$ 94.0% $700.00

Depretiation Fixed Assets Profit ROCE

Quality Yield Variable Cost/Unit 4,000,000 200,000,000 9,384,033 4.56% 0.69%97.0% $385.00 4,071,429 200,000,000 10,805,573 5.25%98.0% $385.00

Labor & Other fixed costs NOWC Capital Employed

Pct Change 23,280,330 6,000,000 206,000,000 0 23,280,330 6,000,000 206,000,000

7,089

0%10%20%30%40%50%60%70%80%90%

100%

1

Baseline

Quality

Performance

Availability

NetProduction 7,319

0%

20%

40%

60%

80%

100%

1

WITH IMPROVEMENTS

Quality

Performance

Availability

Net Production

ROCE

Profitability

OEEMaintenance Cost

Revenues

4.20%

4.40%

4.60%

4.80%

5.00%

5.20%

5.40%

1 2

Financial Impact:

Profitability &

Return on Capital

Employed (ROCE)Availability

Performance

Quality ROA = Income / Assets

Q: What is the impact of improving Operator Effectiveness at your facility?

A: Small improvements in Availability, Performance, and Quality can result in large bottom-line financial impact

Availability improvements: How many spurious trips, process upsets, and unplanned outages can be avoided with better

situational awareness, improved navigation, better control visibility, effective alarm management, and better contextual information?

Performance improvements: How much time can be saved with improved navigation, better asset performance visibility, effective

alarm management, better contextual information, and streamlined work processes?

Quality improvements: How many environmental events, regulatory fines, safety events can be avoided with better situational

awareness, improved navigation, better control visibility, better asset performance visibility, effective alarm management, and better contextual information?

Mark Bitto / ABB Inc / PSPG / CIBO Technical Focus Group ...

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