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PBFX322 Workflow – Alarm Handling Made Easy

PBFX322 Workflow – Alarm Handling Made Easy. Presenters: Dirk Kozian Peter Guhl Steve Golemme Bimal Mehta. Invensys Enterprise Control Offerings. Corporate Systems. Industry Solutions Services: Consulting, Project Execution, Learning,

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PBFX322 Workflow – Alarm Handling Made Easy

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  1. PBFX322 Workflow – Alarm Handling Made Easy Presenters: Dirk Kozian Peter Guhl Steve Golemme Bimal Mehta

  2. Invensys Enterprise Control Offerings Corporate Systems Industry Solutions Services: Consulting, Project Execution, Learning, Operational Improvement, Maintenance & Support Partner Ecosystem Corporate Software Applications Invensys and Third Party Manufacturing / Production Operations Automation Invensys and Third Party Enterprise Control System IT Platform Integration and Collaboration Platform

  3. Where The Offerings We Will Discuss Fit Within TheInFusion Enterprise Control System Execution Integration & Collaboration Platform Enterprise Asset Management Mobile Workforce Management Manufacturing Execution Systems Batch Performance Software Applications Enterprise Manufacturing Intelligence Asset Performance Performance Measurement and Reporting Enterprise Integration Visualization Quality Optimization Workflow Advanced Process Control Simulation / Optimization Design Operator Training Third-Party Offerings Open Device Integration Web Portal Control Automation Software Applications DCS PAC SCADA HMI Application Toolkit Safety Turbomachinery Control Safety Instrumented Systems General Purpose Safety Historian Measurement & Instrumentation Recorders Instrumentation Controllers

  4. Pillars of Operational Excellence and Focus of This Discussion Operational Excellence Level 3 (Multi-plant/Multi-site) Environment And Safety People Level 2 (Plant Floor/Area) Asset Level 1 (Resource/Asset) Control

  5. Agenda: Workflow-AlarmHandlingMadeEasy • Objective • “What is Workflow?” – Introduction • IA Series Overview • Alarm Management – Current Situation • ARM (Alarm Response Manager) Use Case • Problem Statement & Customer Expectations • Potential Use Case of Alarm Response Management • Value Proposition • ARM System Architecture & Application Overview • Solution • Use Case Scenario (s) – Visual & Summary • DEMO • Opportunity Q&A

  6. Objective • Why Workflow • Why Alarm Management with I/A? • Opportunities

  7. Current Situation • A large part of the issue is that control systems have three major inadequacies: • Control system products have traditionally focused on the “alerting” the operator. Additional information is needed to properly “inform and guide” the operator. • We have focused on analog (alarm trip point) and textual information (consequence). The third information type, “procedures” has not been adequately addressed. • Alarms are only useful when designed for a specific operating condition, we have lacked useful logic engines to define the states and apply rules. • The scenario has special implications, as through this demonstration, Invensys would offer to its existing I/A series customer base a new dimension in Operator responses to Alarms, which is necessitated and guided by some of the latest ISA directives

  8. Workflow – An Introduction

  9. Enterprise Control Defined Corporate Systems Corporate Operations Management Software Invensys and Third Party Performance Application Services Visualization Execution Control Supply and Demand Chain Safety ERP Optimization Governance Measurement and Instrumentation Manufacturing / Production Operations Automation Systems and Equipment Invensys and Third Party Enterprise Integration Open Integration BPM Workflow ArchestrASystem Platform IT Platform

  10. Economic environment has changed … Enterprises need to be • Highly competitive • Doing more with less • Respond to changes/requests rapidly • Efficient to the highest degree

  11. There will be Exceptions. Always! HOW WILL YOU HANDLE THEM?

  12. Planned & Unplanned Events! All Events Occurring in All Facets – All Functional Domains

  13. Productive, Efficient, Repeatable Original Event Response Productive After New Process Efficient Optimized Workflow Repeatable Optimized Workflow Knowledge

  14. ArchestrA Workflow Software - The Workflow Management System for the Industrial Market Business Planning Process Field Data Collection - Built on top of an existing, robust, scalable BPMS - A natural extension of the IDE ERP - Acts as the glue between systems Equipment Maintenance - Leverages the human capital Maintenance System Control System Manual Production Steps Production Process

  15. ArchestrA Workflow - Architecture Custom Enterprise Console Mobile Phones Outlook PDA Messenger Desktop InTouch Microsoft Integration Enterprise Control System Connectors Foxboro Control Software Wonderware System Platform SIMSCI-ESSCOR ROMeo 3rd Party Applications Wonderware IntelaTrac Wonderware MES Wonderware EMI BPM/Workflow Services Engine Forms BAM/KPI Process Management Integration Backoffice Integration Enterprise Integration

  16. I/A Series Overview

  17. “Invensys offers one of the broadest portfolios of products and services in the process automation industry. Their commitment to customers provides an evolutionary migration path to the latest technologies without requiring customers to abandon their investment in earlier I/A systems” Larry O’Brien ARC Advisory Group The I/A Series System Success Story • Established in 1908 – Foxboro wrote the book on process control • More than $18 billion install base • Systems installed in more than 180 countries • The most comprehensive, open and scalable automation platform • Serving all major markets

  18. The I/A Series System Know-How • Know How to take care of customers • Global 24x7 support • Total lifecycle support • Best in class migration paths • Know How to design superior plant-wide • control systems • Long history of open standards • Continuously current philosophy • Ease of use • Top-to-bottom fault tolerance • Plant-wide integration of data from all sources • Know How to control plant-wide processes • Superior application knowledge • Proven project execution • Enhanced Cyber Security “Foxboro I/A has made an important contribution to modernizing the approach to operation and maintenance in our plant.  It has brought us out of the past and ready for the future.” Kevin Kinsella Production Supervisor Technical, Ontario Power Generation Inc.

  19. Alarm Management – Current Situation

  20. Invensys Operations Management Alarm Lifecycle Invensys Alarm Management Services Alarm Management Assessment Alarm Management Design Alarm Management Implementation Alarm Management Optimization Services Elements Advanced Alarming Operator Survey Alarm System Monthly Audit Initial Alarm System Performance Assessment Alarm Philosophy Workshop Chattering Alarm Reduction Alarm Philosophy & Functional Design Spec Advanced alarming Assessment Alarm Rationalization Alarm Rationalization Implementation Alarm Rationalization As Needed HMI Assessment Alarm Rationalization Implementation HMI Functional Design Spec HMI Design Implementation Final Alarm System Performance Assessment Implement ARM Knowledge Transfer

  21. Invensys’ Alarm Management Goal • Provide operators tools that will: Alert Inform Guide

  22. ARM: Alarm Response Manager • Application that is launched by operator from the standard alarm display and process graphics. • Provides a browser window to an alarm database or document the informs and guides the operator. • Goal: Help the control room operator remediate or mitigate an abnormal situation.

  23. Use Case / Demo

  24. Problem Statement & Customer Expectations • Control System Operators are often constrained in effectively dealing with Plant Alarms. Primary reason for this situation is attributed to inadequate empowerment of Operators in the form of lack of access to right context information specific to current alarm, past history, known cause and consequences, SOPs etc… • From a regulatory standpoint, that workflow functionality is expected (ISA 18.02) or required (49 CFR 195). • Clients expect less expensive and shorter implementation times than those provided in the recent years.

  25. Value Proposition • Integration of alarm management and workflow. • Integration of engineering practices so that solution is robust, less expensive, and require less client involvement. • An external application that can facilitate alarm rationalization, seamless accessibility on demand to control system operators from their operating console, providing ready access to Alarm specific information and recommended actions at the ease of a click. • Accomplishing the goal has often resulted in significant improvements in manufacturing environments. On average the results are: • Abnormal Situation Avoidance – Reduction of over 50% • Manufacturing Cost Reduction – around 2% • Quality Improvements – Variability reduction of one sigma

  26. System Landscape Proof of Concept was done with I/A and ArchestrA Workflow on the same system. ARM DCS System Rationalized Alarm Database Operator Console

  27. Application Overview • Looks for • Alarm Info Rationalized Alarm Database ARM ArchestrA Workflow Application Alarm Manager • Launches ARM • Displays Rationalized • Alarm Info Operator • Highlight Deviations • Rationalize Alarm • Take Corrective Action I/A Environment

  28. Solution • Display Alarm Rationalization Summary Information • Cause, Consequences, Corrective Actions, Impacts • Provide access to relevant electronic support documentation • Associate SOP, drawings, escalation procedures • Association, View and Launch of workflows Potential Opportunities to enhance this use case • Executes Alarm Audit and displays audit results • Audit Priority, Trip Points, configured state, inhibit state • Provides configuration options for periodic Alarm Audits • Provide Rationalized Alarm Database Enforcement Capabilities

  29. Frozen Transmitter Use Case Scenario

  30. IA Environment Temperature Down Operator IA CAD Freeze Warning Alarm Process Parameter Breach Initiate WO Notification ArchestrA Workflow EAM System/ Personnel (SAP/ Avantis/ Maintenance Operator) Alarm Info & Recommended Actions Escalate Workflow Initiation No Workflow Closure • Action Taken on time? Yes

  31. Frozen Transmitter ScenarioABC Refineries Visual (approx. 7 mins) Note: Internet connection needed to view the video. Summary of the same is provided in the following slides.

  32. Frozen Transmitter Scenario - Summary • Scenario: Early winter storm ushers in strong winds and extremely cold temperatures. • Process parameter breach: Transmitter low ambient temperature alarm triggers, “Freeze Warning.” • Smart transmitter integration with DCS provides context rich information flow from transmitter into DCS, including transmitter ambient temperatures. • Operator is alerted via IA Alarm/Alert subsystem: • At the operator workstation both an audible alarm sounds and ALARM soft key flashes red. • Operator views IA CAD (Current Alarm Display). • Either operator selects ALARM soft key or operator looks at monitor with CAD already called-up.

  33. Frozen Transmitter Scenario - Summary (Cont’d.) • Operator initiates ARM for specific alarm • Operator selects/highlights the specific alarm on the CAD • Operator selects new button on CAD, “ARM,” initiating ARM ArchestrA Workflow application • ARM application is passed alarm context information as indicated by the operator selected alarm on the CAD • Operator is prompted to confirm their selection and initiate workflow for selected alarm • Prompt can either be in the form of a dialogue box appearing on operator screen or via email/SMS prompt or all of the above • Operator confirms to proceed with recommended workflow for specific alarm

  34. Frozen Transmitter Scenario - Summary (Cont’d.) • Upon confirmation by operator, Work order request notification is sent. • Notification is automatically sent to connected EAM system (e.g. Avantis, Maximo, SAP) • If no integrated EAM is configured then responsible shift personnel are sent SMS/email for manual request to process maintenance work order request • A timer is set, in either case, for time-out escalation of work order approval/ acceptance • Maintenance inspects/repairs/completes work order • Operations are notified of work order completion including report and audit trail of all activities NOTES: • Solution mitigates ruptured piping/vessels due to quick action and follow-through in response to alarm. • If no EAM system is available an ArchestrA Workflow Form will be used to collect & distribute work order status info.

  35. Extension of the use case • In addition to the above discussed or any of the Use case, we could have scenarios where the Operator could trend historical data before calling for I/E help to provide additional troubleshooting information. Like, the Alarm Info having, • Causes • Impulse Piping • Loop Wiring • Electronics • Consequences • Loss Production, Loss of Critical Process Information • Verification • Check local gauge

  36. Additional Content (Cont’d.) • Recommended Actions • Impulse Piping: • Check to ensure that the blocking valve is fully open. • Check for trapped gas in a liquid line or trapped liquid in a gas line • Check to ensure that the density of the fluid in the impulse line is unchanged. • Check for sediment in the transmitter process connection, if found flush. • Check for frozen process fluid in the process connector. • Check for trapped gas in a liquid line or trapped liquid in a gas line. • Loop Wiring: • Check for intermittent shorts, open circuits, and multiple grounds. • Check for adequate voltage to the transmitter. • Electronics: • Check for EMF interference • Check damping • Replace the output board and recalibrate the transmitter • Replace the transmitter

  37. Opportunity Q&A • How do I ARM my plant? • Alarm Management • Help you develop your Rationalized Alarm Database • Alarm Management • AOM, Atypical Operations Management, Help mitigate & return to normal • Emergency Management • Fires, Chemical releases, spills, … • Safety Procedures • Lock Out Tag Out, Vessel Entry, … • Security Procedures • Time Sensitive Procedures / Activities

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