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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
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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
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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
Slide40
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