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Introduction to UReasonIntroduction to USE
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Achieving Operational Excellence
UReason is
Anglo-Dutch Company with offices in Leiden, Maidenhead and Paris
Delivers real-time applications and solutions in the area of Operational Excellence
Customers in Europe, North-America and Middle-East. Industries: Oil & Gas, (Petro)chemical, Traffic, Energy and Utilities
“We Combine our Expertise and Technology with that of our
customers to improve Operational Excellence”.
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Achieving Operational Excellence
Customers of UReason
Operational Advisories:– Sabic– DSM– Remote Surveillance:
• Siemens Power Generation• Vestolit• Shell Global Solutions/NAM
Alarm Management:– BASF– BP– KPE– OMV– Siemens Oil & Gas– LyondellBasell– Total E&P– Anglian Water
Simulation:– WaterSpot: DZH/PWN/Waternet
/ABB/DHV/Vitens/TU-Delft– DISCONTO: PWN/DHV/TU-Delft/RIVM/
Vitens/Dunea/Brabant Water
Active Participant in:
• ANSI/ISA S18.02 Standard• ISA S18.02 TR Development• EEMUA 191 Guideline
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Achieving Operational Excellence
Products of UReason
USE, OASYS-AM, UDesign : Based on Common Product Platform
OPC DA ODBC/JDBC Webserver CSV
Process Device Fuzzy Logic Scripting EPDA
Restricted Version Of Product A
Product BProduct A
Product Platform
Visualization Components Intelligent Components
License Components Offline Data Configuration
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Product C
OEM Solution Based On Product A
VAR Version of Product B
AnomalyDetection
Serial Port
FFT LogicDesign
Product C (Customer X Edition)
Neural NetsAnomaly Detection
New Product For Customer X
?
?
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Achieving Operational Excellence
Engineering environment for companies wanting to create intelligent solutions
Engineers “Expert Toolbox”
USE – UReason Solution Environment
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Achieving Operational Excellence
USE – USP / Benefits
Unique selling points:Out-of-the-box functionality– Interfaces – Data-storage – Rules– Explanation facility – Web access– Model based reasoning and
management– Structured approach– Generic (write once, reuse)
Customer (typical solution provider) benefits:– Reduced engineering time– Easy integration with a wide variety of underlying automation systems
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Achieving Operational Excellence
OASYS-AM – Intelligent Alarm Management
Supports organisations in their alarm management, from reporting to dynamic reduction and intelligent predictive
alarming
– Play-back Incidents and upsets– Identify states, causes & effects– Induce rules from pattern mining– Intelligent Alarm engineering
– Reduction rules, cause-effect trees, – State detection diagrams, etc
– Provide advisories (alerts) – Reduce alarms in real-time– Tune operational advisories – Monitor operator actions – Generate EEMUA standard reports
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Achieving Operational Excellence
OASYS-AM - USP / Benefits
Unique selling points- Solution covering full scope: from alarm management, over
engineering of logic to reduce and predict alarms to real-time alarm handling (hiding, diagnostics, early event detection)
- Out-of-the-box functionality results in reduced engineering (configuration), installation and interfacing efforts
- Supplier independent, works with all major DCS and SCADA systems
Customer benefits (typical end-user):- One-stop-shop for complete solution + required services if needed- Reduced alarm load enables reduced staffing (up to unmanned
operations)- Technology enables dealing with increasing complexity of
automation, control and safety systems- Best practices (procedures, diagnosis, predictions) put into action,
24x7- Reduced cost of ownership as the customer can maintain and
extend the application and some maintenance work can be automated
OASYS-AM has strong presence in Oil and Gas Markets, where costs of poor alarm management are high:
– Unplanned trip due to a missed alarm: €400.000– Trips about one a day on a new plant which could be prevented if
there were less nuisance alarms– Release of gas resulting in complaints– ARC ARC-Strategies April 2002 - “A CCM application can add 5% or
more to the profits of a manufacturing plant by detecting and avoiding critical conditions before they occur, thus reducing the need for emergency shutdowns.”
Alarm KBLMFW
Product A
Alarm Data
Alarm Configurations
Chattering Alarms
Eclipsing Alarms
Alarm Patterns
Alarm Causalities
Alarm Reduction Rules
Live Alarm Data
Alarm Settings
Reduced Alarm Data
Operator(s)
Process Control Engineer/Technologist
New Rules Reduction Achieved
Alarms Configurations
EquipmentFailure
Human Errors
Control failure
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Achieving Operational Excellence
UDesign – Design Validation Environment
Combines the on-line rule engine and simulation capability of UReason’ intelligent platform, with the ability to capture and validate engineering designs
Functionality is especially focused on replacing legacy paper-based design workflow
Superior design tools – Huge increase in productivity when compared to
legacy computer or paper based systems – Better design, less mistakes– Complies with IEC 61131-3 definition for visual
definition of logic systemsOn-demand Simulation
– Validated design BEFORE handover, leads to huge reduction in rework and engineering time.
– Can easily be linked up to real-IO and alarm generation for end-to-end validation
Customized workflow– Matches customer needs, aids acceptance, leads
to roll-out adoption– Use UReason’s Product Platform so can be easily
adapted to customers workflow/design process
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Achieving Operational Excellence
Common Product Benefits
Goal: Optimise production, reduction of process upsets & disturbances
ROI: Complying with state laws/regulations– Safety/security potential reduction of insurance premiums– Preventing upsets emission reductions, avoiding production losses– Reducing information overload less operator stress, avoiding burn out of
most valuable resources– Maintaining licence to operate avoid destruction of capital, avoid
equipment damage
ROI: Lower cost of ownership– Reduction engineering time– Ties into preventive maintenance– Ties into asset management
Contributes to operational excellence
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Achieving Operational Excellence
USE Typical Environment
Raw Data Processing
External System
DCS, SCADA, Historian, PLC
External Systems Interface
End U
ser Interface
Raw Event Processing
Process Model Event Services
Reasoning
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OPC DA OPC A&E
Process Variables Raw Events
Domain ObjectsDomain Topology Event Management/handling
Engineer Interface
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ODBC….
Developer UserThin client
Thick client
Licence/Mode:
Engineering
Thick client
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Achieving Operational Excellence
USE - From Data to Point Solutions
DataHandling
Model(s) Rules Results
Step 1 Step 2 Step 3 Step 4
Deploy & MaintainSolution
Step 5
Data Access & Processing
Step 1 – Access to Process and/or Alarm and Event DataAdd-ins are available to access data from various data sources such as file, databases and automation layers
– File – CSV– Databases – ODBC/JDBC Compliant– Automation Layers - OPC Data Access
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Achieving Operational Excellence
Data Handling
Historical data can be played back at normal or increased speeds
Data has– Validity Status – determined
by data processing rules– Expiry Status – determined by
ExpirationPeriod settings
Data Processing Rules can be used to calculate replacement values for missing data, invalid data or derived data
History of data processed can be kept for RT trending
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Achieving Operational Excellence
Configuration
Setup of IO can be done automatically
– F.ex. In case of IO from an OPC DA, files can list the OPC Items and configurations to use (instantiate)
Special – OPC Servers instances Simulation Mode – allows you to feed tag data for OPC Items from file
– Often used to run historical data through a solution for FAT/SAT
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Achieving Operational Excellence
Examples
Database Access– SQL Server
• Wonderware InSQL• Yokogawa Exaquantum
– Oracle– MySQL
OPC Data Access– Honeywell TDC3000, Experion– Emerson Delta V– ABB 800x– Invensys IA– Siemens S7 PLC– OSISoft PI– Kepware– Matrikon– Siemens WinCC– Wizcon– Etc. etc.
Small – to Large200 – 20.000 IO
With and without failover
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Achieving Operational Excellence
USE - From Data to Point Solutions
DataHandling Model(s) Rules Results
Step 2Step 1 Step 3 Step 4
Deploy & MaintainSolution
Step 5
Map data to Object Model
Step 2 – Models: represent a part of the environment a USE solution can analyseModels consist of the structure and behavior of the domain being analyzed:
– The structure describes the components (objects) in the domain and how they are interconnected and aggregated
– The behavior consists of the relationships between the inputs and outputs of the components and their aggregates
No Coding, compiling or linking classes can be
created (and instantiated) on the fly
OO Models with connectivity and containmentship
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Achieving Operational Excellence
Model Example
E.g. when modeling a manufacturing process:
– Each component in the model will be classified: A Pump, A Compressor, A Pipe, etc
– Interrelationships (connections) between each unit/process would be defined: Pump P1F has one stream input, one stream output, one power connection
– Links to live/simulated data sources/sensor readings to attributes of items in the model would be set up: the flow rate of Pump P1F connected to OPC TAG P1F237
Component
Relationship
Live/SimulatedData
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Achieving Operational Excellence
Classes
Basis for constructing Models are classes that represent the items you wish to diagnose or analyse
Classes can be defined for Domains or specifically for Scenarios
Classes are the templates (blueprints) for the objects (instances) you require in your model
A Class Definition can have:– Fields: e.g. the Level of the Tank – Representation: e.g. a Tank looks like an open rectangle– Animation: e.g. when the Level of the Tank is above 50 the
Tank highlights red– Instances: e.g. our Domain has two Tank instances: Tank302
and Tank303
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Achieving Operational Excellence
Model Example
Siemens APSS (I&S)Model =
– Units/Equipment/Sensors– Logical Model of Scenarios
• Wind directions• Sensor groups
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Achieving Operational Excellence
USE - From Data to Point Solutions
DataHandling Model(s) Rules Results
Step 3Step 1 Step 2 Step 4
Deploy & MaintainSolution
Step 5
Data & Model Driven Rules
Step 3 – Setup the rules that:– Detect certain unwanted symptoms/events– Diagnose possible root causes– Predict failures
USE contains an set of Rule types and Rule blocks to setup the solution logic
Good Model Pays Off Allows for Generic (Model Based) Rules
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Achieving Operational Excellence
Setup the Rules
Rule Definitions allow you to:– Detect abnormalities– React upon certain events– Further analyse a
hypothesis by questioning users when problems arise
– Pro-actively predict certain events
– Etc. etc.Rule Definitions can work with models and use the relationships defined to reason with:
– Use containmentship– Use connections
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Achieving Operational Excellence
The Rules
Different Rule Types– Data Validation Rules, – Data Reduction Rules– Event Reduction Rules– Symptom/Cause Rules– State Diagrams/Event Fault
Trees– Decision Support Rules
Libraries of rule blocks– Depending on the type of rule
you construct different palettes are available containing the building blocks for a rule
– Palettes available are rule context sensitive
– Add-ins installed can extend the palettes available – i.e. extend the available rule functionality of an installation
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Achieving Operational Excellence
General Concepts
Rules can be seen as data flow diagrams
– Building blocks for these ‘diagrams’ are cloned of Palettes
– Diagrams can have layers – depth depends on the Rules Blocks used
Connections in rules follow a ‘syntax’:
– You can connect like to like
– Object connections accept ‘all’
Rule definitions are active or not active (installed/de-installed)
Contains detail
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Achieving Operational Excellence
Categories
Categories of Rule Blocks:– Calculations
• Maths• Statistics
– Logic/Flow• Boolean blocks• Gates & Toggles
– Model Operations• Containmentship,
Connectivity, Type Checking, Object values, Parent Objects etc.
– Events• Event Generation• Event Triggering• Mail notification
– Specials:• Decision Support Agent• Topology Agent• State Transition Diagrams• Animation• Fault Tree Definition
Standard Functionality– 60+ Palettes (no Add-ins installed)– 300+ Blocks (extended each
release)
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Achieving Operational Excellence
Configuring Rule Blocks
General concept: drag-drop-connect-configureConnecting rule blocks – follows connection syntax, typed connections for:
– Booleans– Conclusions– Events– Numbers– Objects– Strings
Most rule blocks are configured through their Properties
– Nearly all rule blocks provide descriptions on general use and configurations
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Achieving Operational Excellence
Configuring Rule Blocks
Some rule blocks provide special purpose editors for configuration and/or viewing run results (in real-time)
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Achieving Operational Excellence
Adding Rule Blocks
Using the Scripting Block– Variable inputs, outputs– JavaScript executes
block’s function– Depending on the use can
be incorporated into a Reusable Rule Block Definition
– Available in Add-in: UScript
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Achieving Operational Excellence
USE - From Data to Point Solutions
DataHandling Model(s) Rules Results
Step 4Step 1 Step 2 Step 3
Deploy & MaintainSolution
Step 5
Results
Step 4 – Results of Rule Execution can be: – Events – within the USE environment– Email – if SMTP access is available– Control (writes) via ODBC/JDBC, OPC or
custom interfaces
Results can be validated prior to deployment using
– The build in Simulator– The Rule Validation Add-in
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Achieving Operational Excellence
Results Example - Events
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Achieving Operational Excellence
Event Lifecycle
Events have a life-cycle, they are:
– Created– Used/Referenced– Changed/Stored– Disposed
The lifecycle of an Event is influenced by:
– The User• Acknowledge an Event,
deletes an Event etc.– The Environment for which
the Event was generated• Event text changes• Condition that raised
event no longer exists
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Achieving Operational Excellence
The Simulator
USE includes a feature that allows you to playback, at increased speed, known incidents stored in Data and Event Logs
– The Simulator is helpful to test rules, rule strategies and analyse or diagnose past incidents
– Log Processing Rules have special configurations to allow you to use exactly the same timestamps as used in your data and event logs (WaitForActualStartTime)
Results for specific simulations can be analyzed separately (the system is Simulation Run aware)
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Achieving Operational Excellence
Rule Validation Add-in
The Rule Validation Add-in allows you to graphically analyse events, generated by rules, for a given model object for datasets
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Achieving Operational Excellence
Analysing Rule Results
Further to the Rule Validation UI logging and a graphical rule debugger assist the engineer in troubleshooting/analysing results
The Debugger allows you to graphically debug a Rule Definition (Query, Detect, Inform, Action)
– When debugging a rule is ‘configured’ to support looking at the rule’s execution state(s) and stop at the Breakpoints you define (toggle)
– You can set a breakpoint in your rule schemes to halt execution on a specific element, immediately before it is executed
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Achieving Operational Excellence
USE - From Data to Point Solutions
DataHandling
Model(s) Rules Results
Step 5Step 1 Step 2 Step 3
Deploy & MaintainSolution
Step 4
Deployment
Step 5 – Point Solutions developed can easily be deployed and maintained
– Solution (IO/Model/Rules/UI) can be exported/loaded onto deployment hardware
– UI Setup & User Support build in• Thick UI can be setup for controlling users• Thin UI for surveillance users
– Build in change tracking, for deployed solutions (know what has changed)
– User can provide in-line feedback to generated events using annotations
BUILD IN ADVISORIES
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Achieving Operational Excellence
Some Examples
Following slides contain some examples of applying UReason technology and services
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Achieving Operational Excellence
Example: Northsea Gas producer
Scope of Supply:- Alarm Management Survey- Philosophy Development- Support Alarm Rationalization- Performance Auditing- Advanced Alarm Management System for Onshore Centralized Control Room
DCS: Foxboro IAA&E Historian: TiPS LogMateAlarm Reporting: OASYS-AMAdvanced Alarm Management: OASYS-AM
Alarm reduction on 4 platforms, Visionary Approach for Centralized Control Room
Alarm reduction on 4 platforms, Visionary Approach for Centralized Control Room
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Achieving Operational Excellence
Overview of the reduction realized, varying between 30% – 65%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
300 Board Reduced 600 Board Reduced 800 Board Reduced All Boards
Next generation alarm management
Example: LyondellBasell
Scope of Supply:- Rule Discovery from Historical Data- Alarm Display Replacement- Alarm Predictions in Control Room
Corporate Agreement – Advanced Dynamic Alarm Management
DCS: Emerson DeltaVData: TiPS LogMateEmerson OPCAdvanced Alarm Management: OASYS-AM
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Achieving Operational Excellence
Example: Chemical Plant Germany
Proactive 24x7 information on gas leaks
Vision/Smell & Sound Sensors Combined
Operators don’t have to do a 12 hours plant inspection
Important for keeping licence to operate
Operator Advisories
Interfaces: Emerson, ABB, Siemens
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Achieving Operational Excellence
Example: Refinery Netherlands
Scope of Supply:
- Alarm & Event Historization- Alarm & Event Reporting- Alarm Awareness Workshops - Alarm Philosophy Development- Master Alarm Database- Alarm MOC
DCS: Honeywell TDC, Foxboro IA, Yokogawa CSHistorian: SQL Server
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Achieving Operational Excellence
Example: Refinery Netherlands
Scope of Supply:
- Consultancy - Alarm Awareness Workshops - Alarm Philosophy Development- Setup Master Alarm Database- Vendor Selection
- A&E Historization- A&E Reporting- Master Alarm Database & MOC
DCS: Honeywell TDC, HIMA/MagLog ESD
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Achieving Operational Excellence
Siemens – Process Real-Time Historian PIMAQ
SISOG PIMAQ System Embeds OASYS-AM
PIMAQ Examples:- Maersk Al-Shaheen FDP 2000- Maersk Al-Shaheen FDP 2005- Maersk Halfdan- Petrobas FPSO Piranema- Venture Oil FPSO Hummingbird- Statoil Snorre A, Snorre B- ConocoPhillips EldFiks- Hydro Njord A & B
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Achieving Operational Excellence
Siemens - PIMAQ
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Achieving Operational Excellence
Siemens - PIMAQ
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Achieving Operational Excellence
Electrical Submersible Pump (ESP) Monitoring
About 15 to 20 percent of almost one million wells worldwide are pumped with some form of artificial lift more and more employing electric submersible pumps
ESPs operate under varying working conditions: High temperature High pressure Scaling/Waxing
…and have a short lifeRuntime lifetime varies between 50
days avg to 1500 days.
Consequences of losing an ESP– Product Loss/Deferment– Expensive to Pull and Replace
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Achieving Operational Excellence
Electrical Submersible Pump (ESP) Monitoring
Generic EED & RCA:– Sand Production– Surface Choke– Tubing Leak– Scaling
Specific EED & RCA:– Location Specific– Pump Configuration
Specific
Early Event Detection (EED) and Root Cause Analysis (RCA)Early Event Detection (EED) and Root Cause Analysis (RCA)Generic Means:
The Same Solution can be applied over-and-over again
to 1 or Many ESPs
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Achieving Operational Excellence
Proactive Asset Management (Water)
Achieved by highlighting variances in normal operating parameters e.g. pump flow, level, etc:
– E.g. Pump performance degradation, number of stop and starts of the pumps can be used in combination with the number of hours running during a day to determine if a pump is degrading
Inferential measurement and sensor validation which identifies drift on process plant requiring subsequent intervention
– difficult-to-measure parameters can be derived from existing instrumentation. This type of information can be used to track BOD, COD or bacteriological load on-line and so improve consent monitoring and remedial action to ensure consent compliance.
– E.g Inlet flow and suspended solids can be used as model inputs to predict BOD with reasonable accuracy
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Achieving Operational Excellence
Drinking Water Purification Simulator
• Simulator– Object model– Hydraulic model – Water quality model– Control model
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Achieving Operational Excellence
Water Purification Simulator USPs
Technologies: USE + external models from partners
Unique selling points:Developed in conjunction with water companies and other industrial partnersGeneric simulator provides Custom-off-the-shelve simulatorSpecific simulator can easily be tailored to customer’s processes¼ of the price of a simulator in chemical, oil & gas
Benefits for the customer (water company – engineering agency)Training of operators, regional managers
(off-line)On-line evaluationEducationVirtual commissioning of process
automation systemTesting of control strategiesProcess-control improvementWater quality improvement
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Achieving Operational Excellence
Water Safety – Long Term NL Funded Study
Distribution, Control Training and Operations
– Understand the relevant chemical and microbiological processes in the distribution network.
– Develop water quality models to predict quality parameters
– Assess water quality in the whole network to prevent public health risks
– Develop a scenario based calamity simulation system to experiment and understand acute changes in water quality.
– Use calamity simulation to train and educate operators in handling events.
– Deploy real time state of the art water quality sensors.
– Use model integration between process automation system and simulator/models for consistency and efficiency.
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Achieving Operational Excellence
Proactive Asset Management General
Using UReason’s Technology : General Statements– Generic Rules can be defined for each asset type
• i.e. implemented once but valid for all the sites using the same asset type
– Can easily integrate with DCS/SCADA, backend systems and alarm databases, etc to infer asset state from different data sources
– Rules filter bad data– Rules can apply state based reasoning;
• e.g. take into account site criticality, site location, time of the year, relation to other assets
– Integrate asset criticality register– Results can be pushed to extend alarm information and/or
influence Maintenance management systems
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Achieving Operational Excellence
Contact Details:
UReason LeidenPompoenweg 92321DK Leiden071-5281700www.UReason.com