Controller Effectiveness: Alarm Management and High Performance HMI
Bill Hollifield Principal Alarm Management and HMI Consultant for PAS
API Control Room Conference
October 2009 San Antonio, Texas
Slide 1
Controller Effectiveness Resources
Bill Hollifield Principal Alarm Management and HMI Consultant for PAS
ANSI/ISA 18.2 Management of Alarm Systems for the Process Industries
SOON: API RP-1167 Alarm Management For Pipeline Systems
Slide 2
Controller Effectiveness: Support Factors
This Presentation:
Effective Alarm Management
Very Effective Controller!
Control Loop Performance
High Performance HMI
Note from Bill: Arent we all tired of the 3-legged stool analogy?
Slide 3
Related ISA Standards
ANSI/ISA18.22009 Management of Alarm Systems for the Process Industries Begun 2003, Released June 2009 A vital and essential next step for alarm management !
ISA 101 Human Machine Interface In early draft stage Release Date 2011+???
ISA-18.2 has: A framework of alarm management life cycle steps and activities Mandatory practices Recommended practices Some additional content will be published in follow-on Technical Reports (2011-2012)
The Standard does not have: Detailed or specific How to guidance. That is not allowable content for a standard. Work Practice Examples Specific method recommendations Specific method details
The WHAT
Not the HOW
Slide 4
ISA-18.2 Regulatory Impact
Does ISA-18.2 Apply to You? YES if you have a DCS, SCADA systems, PLCs, Safety Systems, or anything where a controller responds to alarms! This includes Petrochemical, Chemical, Refining, Platform, Pipelines, Power Plants, Pharmaceuticals, Mining & Metals. Also for continuous, batch, semi-batch, or discrete processes. Regulatory Impact ISA-18.2 is a recognized and generally accepted good engineering practice. (RAGAGEP!) OSHA and other agencies have General Duty Clauses: , The employer shall document that equipment complies with recognized and generally accepted good engineering practices. Regulatory agencies will take notice of ISA-18.2. A regulated industry can be expected to either comply with RAGAGEP or show that they are doing something just as good or better. Grandfathering ISA-18.2 says: The practices and procedures of this standard shall be applied to existing systems in a reasonable time as determined by the owner/operator.
Slide 5
API RP1167 High Points
Alarm: a visible and/or audible means of indicating to the controller an equipment malfunction, process deviation, or other condition requiring a controllers response. The alarm system should be reserved for items meeting this definition. Alarm Philosophy Alarm Systems Proper Characteristics Proper Alarm Prioritization Proper Alarm Documentation & Rationalization Master Alarm Database Roles and Responsibilities Proper Alarm Handling NO UNCONTROLLED ALARM SUPPRESSION ALARM CHANGES BY CONTROLLERS TIGHTLY CONTROLLED MANAGEMENT OF CHANGE Alarm Shelving Advanced Alarm Methodologies overview Alarm System Monitoring and Performance Metrics (TARGET NUMBERS!) Alarm System Audits General Information: SCADA Alarm types and typical features
Slide 6
API RP1167 Alarm System Performance
Alarm Performance Metrics per Controller Position Based upon at least 30 days of data Metric Target Value Target Value: Very Likely to be Target Value: Maximum Annunciated Alarms per Time: Acceptable Manageable Annunciated Alarms Per Day per Controller Position Annunciated Alarms Per Hour per Controller Position Annunciated Alarms Per 10 Minutes per Controller Position Metric Percentage of hours containing > 30 alarms Percentage of 10-minute periods containing >5 alarms Maximum number of alarms in a 10 minute period Percentage of time alarm system is in a flood condition Percentage contribution of the top 10 most frequent alarms to the overall alarm load Quantity of chattering and fleeting alarms Stale Alarms ~150 alarms per day ~6 (average) ~1 (average) ~300 alarms per day ~12 (average) ~2 (average) Target Value
~ <1% ~ <1% 10 or less ~ <1% ~<1% to 5% maximum, with action plans to address deficiencies. Zero, action plans to correct any that occur. Less than 5 present on any day, with action plans to address 3 priorities: ~80% P3, ~15% P2, ~5% P1 or 4 priorities: ~80% P3, ~15% P2, ~5% P1, ~<1% Priority Critical. Other special-purpose priorities (Diagnostic) excluded from the calculations Zero alarms suppressed outside of controlled or approved methodologies Zero alarm attribute changes outside of approved methodologies or MOC
Slide 7
Annunciated or Configured Priority Distribution Unauthorized Alarm Suppression Improper Alarm Attribute Change
The 7-Step Alarm Management Improvement Process A Proven Methodology
Step 1: Develop, Adopt, and Maintain an Alarm Philosophy
Step 2: Collect Data and Benchmark Your Systems Step 3: Perform Bad Actor Alarm Resolution
Always Needed
Often Done Simultaneously
Step 4: Perform Alarm Documentation and Rationalization (D&R) Step 5: Implement Alarm Audit and Enforcement Technology Step 6: Implement Real Time Alarm Management Step 7: Control and Maintain Your Improved System
Needed Based Upon Performance
The WHAT and the HOW A primary focus on improvement of existing systems, with applicability to new systems.
Slide 8
Alarm Philosophy and Analysis
An Alarm Philosophy
(a comprehensive document on how to do alarms right!)
CONTENTS Of An Alarm Philosophy 1.0 Alarm Philosophy Introduction 2.0 Purpose and Use 3.0 Alarm Definition and Criteria 4.0 Alarm Annunciation and Response 4.1 Navigation and Alarm Response 4.2 Use of External Annunciators 4.3 Hardwired Switches 4.4 Annunciated Alarm Priority 5.0 Alarm System Performance 5.1 Alarm System Champion 5.2 Alarm System KPIs 5.3 Alarm Performance Report 6.0 Alarm Handling Methods 6.1 Nuisance Alarms 6.2 Alarm Shelving 6.3 State-Based Alarms 6.4 Alarm Flood Suppression 6.5 Operator Alert Systems 7.0 Alarm Rationalization 7.1 Areas of Impact and Severity of Consequences 7.2 Maximum Time for Response and Correction 7.3 Priority Matrix 7.4 Alarm Documentation 7.5 Alarm Trip Point Selection 7.6 The Focused D&R Option 8.0 Specific Alarm Design Considerations 8.1 Handling of Alarms from Instrument Malfunctions 8.2 Alarms for Redundant Sensors and Voting Systems 8.3 External Device Health and Status Alarms 8.4 ESD Systems 8.5 ESD Bypasses 8.6 Duplicate Alarms 8.7 Consequential Alarms 8.8 Pre-Alarms 8.9 Flammable and Toxic Gas Detectors 8.10 Safety Shower and Eyebath Actuation Alarms 8.11 Building-Related Alarms 8.12 Alarm Handling for Programs 8.13 Alarms to Initiate Manual Tasks 8.14 DCS System Status Alarms 8.15 Point and Program References to Alarms 8.16 Operator Messaging System 9.0 Management of Change 10.0 Training 11.0 Alarm Maintenance Workflow Process Plus Appendices
Alarm Count
Alarm Analysis
(Specific Problem Identification)
Top 10 Most Frequent Annunciated Alarms
180000 160000 140000 120000 100000
100.0 90.0 80.0 70.0 60.0 50.0
43MV022.CMDDIS
43MV010.CMDDIS
43PAH397.OFFNRM
43MV018.CMDDIS
43MV022.BADPV
43MV006.BADPV
43MV024.BADPV
43MV010.BADPV
43MV018.BADPV
Alarms Per Day
Recorded Max. Acceptable (300) Manageable (150)
6000 5000 4000 3000 2000 1000 0
- 8 Weeks -
43FC155.PVLO
We dont need no stinkin rules!
80000
40.0
60000 40000 20000 0
30.0 20.0 10.0 0.0
Slide 9
Cumulative %
Fix Your Bad Actor Alarms!
Top 10 Most Frequent Annunciated Alarms
180000 160000 140000 120000
100.0 90.0 80.0
60.0 50.0 40.0 30.0 20.0 10.0
Cumulative %
Alarm Count
100000 80000 60000 40000 20000 0
Exactly How To Solve Them
70.0
The top 10 alarms usually make up 20% to 80% of the entire alarm system load Many types: Chattering, Fleeting, Frequent, Stale, Duplicate, Nuisance Diagnostic, etc. The methods are simple to learn and apply.
Slide 10
43MV022.CMDDIS
43MV010.CMDDIS
43PAH397.OFFNRM
43MV018.CMDDIS
43MV022.BADPV
43MV006.BADPV
43MV024.BADPV
43MV010.BADPV
43MV018.BADPV
0.0
43FC155.PVLO
Alarm Documentation and Rationalization
Ensures your actual alarms comply with your alarm philosophy (operator actions, priorities, time to respond, etc.)
Documents your alarms (Set Points, Causes, Consequences, Corrective Actions), creating a Master Alarm Database.
Process History
Process History Alarm Statistical Analysis
1.0
0.8
0.6
0.4
P&IDs and Operating Graphics
1 3 5 7 9 2 4 6 11 13 15 17 19 21 23 25 27 29 31 8 10 12 14 16
Data Points
0.2
ESD / APC Expertise
MW
0.0
SOP EOP HAZOP Etc
Fix problems while they are small
Alarm and Control Configuration D&R Software Tools
Plant Experience & Knowledge
Process, Equipment, Operations, Procedures
Slide 11
Audit / Enforce Proper Alarm Settings
Alarm Configuration security is often ineffective. Alarm Creep will occur after D&R unless positive steps are taken. Best Practice: Automatically audit alarm settings to ensure they are not improperly changed.
Summary of Changes in Alarms Needing Management of Change (MOC) Type of Change Alarm Enable State Alarm Trip Points Quantity During Analysis Period 79 181
Alarm Priority Tag Range Tag Execution Status Total
92 121 175 648
Average Per Day
5.6
Slide 12
Implement Real Time Alarm Management
Real-time, dynamic Alarm Management techniques are used to reduce inappropriate alarms caused by changing operating conditions. These techniques include:
Advanced Alarm Shelving (Temporarily suppress alarms safely, with proper tracking and control) State-Based Alarming (Sets of multiple alarm settings that are optimum and correct for all your operating conditions.) Alarm Flood Suppression (Minimize these hazardous conditions! Operator Alert Systems (A toolset for notification of things that should not be alarms.) Detect Plant State Change
Automatically Alter Alarm Settings to Match New State
Slide 13
Control and Maintain Your Improved System
CONTROL - Insure that gains
are not lost over time. Transition responsibilities. Continue to analyze. of Change
Ensure Proper Management
On-Going KPIs
Slide 14
If you havent started already, get started now! Or
Be on the TV news!
Get to know your Regulatory inspectors really well. They just want to help you.
Slide 15
Alarm Management Summary
Poorly performing alarm systems AND HMIs are contributing factors to major accidents and poor operating performance.
Proper Alarm System Management and Alarm System Performance is essential to maximum-efficiency operations.
The solutions to the problems are well known and fully
documented.
So, what about HMIs?
Slide 16
Most Existing HMIs are POOR!
Common, but ineffective process depictions! Numbers sprinkled on a P&ID screen Inconsistent, improper use of color No trends No condition information
Many other poor practices
Slide 17
Poor Alarm Systems and HMIs Encourage Operating by Alarm No way to run a process:
Alarm! Too High!
Alarm! Right of course!
Alarm! Too Low!
Alarm! Left of course!
Slide 18
DCS Graphics Were Introduced in an Era with No Guidelines!
Poor Graphics encourage Poor Operating Practices
Poor Graphics persist for decades!
Many Poor Practices
Slide 19
Vendor Examples are Some of the Worst!
10% of the screen is poorlypresented numeric data,
90% is just a pretty picture
Flashy marketing graphics for selling a system!
Slide 20
Where is the information the operator needs?
5% of the screen is poorlypresented numeric data,
95% is a pretty picture
Slide 21
Other Industries Do It Better
GARMIN 1000 Avionics System
Nearby Airports Engine diagnostics Data on Available Services at Airports Positions of nearby aircraft Real-time weather & lightning Glide Radius Comm & Nav Frequencies Instrument Approaches Much more
Situation Awareness is a High Priority!
Speed Altitude Position Course
Time Enroute Time to next Waypoint Time to Destination
Fuel Remaining Ground and Terrain Proximity
Slide 22
High Performance HMI Benefits
Time after time, poor HMIs are cited as contributing factors to major accidents
Study by Nova Chemicals and ASM Consortium
Task
Detecting Abnormal Situations Before Alarms Occur Success Rate in Handling Abnormal Situation Time to Complete Abnormal Situation Tasks
Improvement
A 5X increase 37% over base case 41% reduction
$800,000 per year savings anticipated on 1 ethylene plant
Slide 23
Data is Not Information: Is Fluffy Sick?
Blood Tests for Fluffy -1 Test HCT Results 31.7%
HGB MCHC
WBC GRANS L/M PLT
10.2 g/dl 32.2 6/dl
9.2 x109 /L 6.5 x109 /L 2.7 x109 /L 310 x109 /L
Answer: Unless you are vet, how can you know?
Slide 24
How About Now?
Blood Tests for Fluffy -3 Test
HCT HGB MCHC WBC GRANS L/M PLT
Results
31.7% 10.2 g/dl 32.2 6/dl 9.2 x109 /L 6.5 x109 /L 2.7 x109 /L 310 x109 /L
Range
24.0 45.0 8.0 15.0 30.0 - 36.9 5.0 18.9 2.5 12.5 1.5 7.8 175 - 500
Indicator Low Normal - High
ABNORMAL VALUES can be seen at a glance.
Slide 25
Data is Not Information:
96.2% XYZ 45.1 98.2 MPPH 221.2 PSI 42.9 48.2 50.6 53.8 54.9 DP INH20 12-15 22.8 1-12 16.3 1-15 39.1
55.7 psig 65.1 155.2
F
Cooler
108.2
190.5 psig 166.1 F 2.77 MSCFH
135.1 psig
Oil 155.2 F Oil 85.1 psi
West
East
W. Vibration: 2.77
E. Vibration: 3.07
Drive: 232.2 amps
22.5%
77.8 MPPH 60.1 22.3% ABC
Lots of Data but Not Much Information!
Poor Presentation
P&IDs are NOT HMIs!
High Mental Workload to Decipher
Slide 26
Show INFORMATION not DATA
Compressor Status Showing Alarm/Shutdown Limits
RECYCLE COMPRESSOR K43
Cool gpm
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
Alarm Indicator Appears here with Priority Level and Color Alarm Range depicted and (for some) shutdown value Desirable Operating Range shown as pale blue area
290 170
38.7 93.1 185 95
120
12 8
170 80
42.7
Show Values
Show Trends
Alarm Range depicted and (for some) interlock value
Buttons for additional functionality
Operational status is obvious at a single glance!
Slide 27
Analog is powerful!
20.1 24.2 25.6 27.8 28.9
Optional: Line color indicates abnormality, alarm is not yet activated
+1.1 +0.8
-0.7
A good profile?
Yes, this one is.
Too hot at the top, too cold at the bottom
Deviation or absolute numbers optionally toggled
A Column Temperature Profile
Slide 28
Trends are Underutilized. EMBED Trends INSIDE Graphics!
7500 10 20
Air KLBH 7400 Econ O2% 5.0 Sec Air in.H2O 7.0
3-4 traces maximum, with rare exceptions.
What is good element next to trend. Color coded with traces.
5000 5000 15
KLBH KLBH in.H2O
20 min 0 0 0
Main Steam 4750
Feed Water 4580 Drum Level -0.5
Implement: AUTO-RANGE AUTO-TIME Show Boundaries of What is Good
2 Hrs -15 3500 3500
Slide 29
Alarm Indications
WORST
480.1 480.1 480.1
Priority 1 Priority 3 Priority 2 480.1 psi No Alarm Indication
Poor
480.1 psi Diagnostic Priority
480.1 psi Priority 3
480.1 psi Priority 2
480.1 psi Priority 1
Poor
480.1 psi Diagnostic Priority
480.1 psi Priority 3
480.1 psi Priority 2
480.1 psi Priority 1
Best: Redundant Coding
4 480.1 psi Diagnostic Priority
3 480.1 psi Priority 3
480.1 psi Priority 2
480.1 psi Priority 1
Slide 30
Status Depiction
Pumps with Run Indication Sensor: Wrong Not Running or Energized Better
STOPPED (Shape is Unfilled and darker)
Bright saturated color is used to indicate abnormal situations only
Running or Not Energized Wrong Better
RUNNING (Shape is Filled and lighter)
Pumps without Run Indication Sensing have a fill matching the background:
Using bright, saturated red and green to show Run/Stop is a poor practice!
Slide 31
Keep it Simple!
Good HMIs Have:
No Animation Limited use of color, reserved for indicating abnormal situations and alarms 2-D, not 3D! No non-relevant internal equipment depiction MANY TRENDS: Integrated Alarm Information Dozens of other factors
Wrong
Wrong
3 Way Valve Symbols
T RIGHT <- Device State
Field ID -> ABC
T <- Tag
Data Attribute T LEFT T RIGHT
ABC
ABC
STATIC
T RUN
RIGHT
T RIGHT
LEFT TRANSIT All Wrong!
T LEFT
INVALID
T INV
UNKNO ERR
T
ABC
ABC T
ABC T
RIGHT
LEFT
Crude FeedT I ABC T TK-21 TRN
ABC T
TRN
ABC T
ABC T
INV
Offscan
ABC
Poor Graphics encourage Poor Operating Practices
ABC T
ABC T
ABC T
RIGHT
LEFT
TRN
INV
Manual
Comm Failure ABC T
ABC T
ABC T
RIGHT
LEFT
MT ABC Alarm Inhibited T TRN S
T ABC T
ABC T
INV
Communication Failure (Stale)
ABC T
ABC T
ABC T
ABC T
RIGHT
LEFT
TRN
INV
Alarm Poor Very Inhibit Vessel Level Off Scan Tagged Indication
Poor IT ABC Vessel ABC T RIGHT T Level IT ABC Indication ABC
LEFT
Better IT ABC Vessel ABC T T TRN Level Slide 32 IT Indication ABC ABC
INV
Tre Ves T Le Indic ABC
ABC
More Poor Practices. Where are these from?
In Document XXX: Color should not be the only indication for information. Then 7 pages later the following is recommended: BACKGROUND FOREGROUND 8 pages later, COLOR COLOR STATE EXAMPLE alarm severity Color Color (priority) is Normal Black Green 1234 addressed with High-High Alarm Black Red 1234 High Alarm Pumping Unit Black Yellow 1234 conflicting Low Alarm Black Yellow 1234 advice to this! Low-Low Alarm Black Red 1234
T RUN <- Device State T RUN <- Device State Non SCADA Controlled Field ID -> ABC
Unknown/Error Data Attribute
T ABC
<- Tag
SCADA Controlled Field ID -> ABC
Black Attribute Data
<- Tag
Blue
1234
ANALOG By the way, what is VALUES the most common color-blindness?
Field ID/ Description Discharge Engineering Units 123.4 HH T Psi 123.4 H Tag Data Attribute
More recommended examples:
Non SCADA Controllable Valve
I
T
OPN <- Device State T OPN T
RUN
IC
RUN
RUNNING
T RUN
STOPPED
T
Field ID -> ABC
UNKNOWN/ I T <- Tag 4 Way Valve Symbols SEQUENCE INVALID I T ABC ERROR
Data Attribute
Suction
Tagged
Device Value
Discharge
Case
OFF
SEQ
INV
ERR
RUN
ABC T
T
T ABC T
ABC T
RIGHT <- Device State ABC ABC IT
T
ABC T
RUN
OFF
SEQ Field ID -> ABC T
INV T <- Tag
ERR
RUN
High-High Alarm High Alarm Discharge Psi 123.4 H Psi Normal Discharge 123.4 Psi Low Alarm Discharge 123.4 L Psi Low-Low Alarm Discharge 123.4 LL Psi
ABC T T
STATIC T O
RUN RUN
ABC
T T
OPEN
CLOSED O
ABC
T T
TRANSIT Data Attribute
ABC
INVALID
ABC
T T
UNKNOWN/ ERRORI T ABC
T T ERR RUN
Deviation
Tagged
Discharge
T OPN
Discha 123.4 R+
OPN OFF
CLS SEQ
T T
TRN INV
INV ERR
123.4 HH
ABC ABC
I TT M
RUN
ABC T
ABC T
ABC T
ABC T
IT M
CLS
ABC T
ABC T
ABC T
ABC T
ABC T
ABC T
ABC T
OPN
OFF
SEQ
TRN
INV
INV
ERR
ERR
RUN
OPN
Discharge 123.4 O Psi
Discharge 123.4 O Psi
Discharge 123.4 O Psi
Discharge 123.4 O Psi
Discharge 123.4 O Psi
Discha 123.4 O
STATICS ABC
T T
ABC RIGHT T
ABC
OPN
RIGHT ABC
T
ABC
OT LEFT
CLS
ABC T
ABC TT
O LEFTT
TRN
ABC TRANSIT O T T
ABC T
INV
ABC INVALID T
ABC
ERR
UNKNOWN/ T ABC T ERRORT
ERR
T
Off-Scan
T OTagged OPN
RUN RUN
T T RIGHT OFF
ABC
RIGHT T
ABC
T SEQ
LEFT
INV LEFT
TRN ERR
T INV
ABC
RUN T
ABC
ABC
Manual ABC
Discharge LEFT 123.4 M Psi
Discharge 123.4 M Psi
Discharge 123.4 M Psi
Discharge 123.4 M Psi
Discharge 123.4 M Psi
Discha 123.4 M
ABC ABC T
T II
ABC T
ABC T I T
T IABC OPN
T IT ABC
T RIGHT
ABC T
I CLS ABC T
T SEQ
ABC T ABC TT
ABC T
II TRNT T
INV LEFT
ABC ABC T
T IT INV
ABC T
ABC T I T
I ABC ERRT
T
ITT
ERR
OPN ABC
T
Discharge Psi 123.4 S Psi Discharge 123.4 S Psi Discharge 123.4 S Psi Discharge 123.4 S Psi
ation ale)
RUN
T RIGHT OFF T
ABC
LEFT
T
ABC
TRN ERR
INV
ABC
fscan
ABC
ABC T
ABC T O
OPN
T IABC
T O ABC RIGHT
ABC
CLS I ABC T
ABC ABC
TRN
T IO T
ABC ABC T
ABC
INV
ABC T
ABC Communications S T FailureT (Stale) OPN ERR OT ABC ABC T
LEFT Discharge
123.4 S
Discha 123.4 S
Slide 33
bit
RIGHT
ABC
T
T
LEFT
ABC
LEFT
T
TRN
ABC
INV
ERR
ABC
LEFT
Is This Really a Good Example?
Station ABC
RUN
RUN
U1 T OPN
I
T
T OPN T OPN
U2
I
T
T OPN L
% Open 123.4 %
V8
V9
V10
V11
V12 T OPN Case 123.4 V7 Psi
T Suction 123.4 Psi DIscharge 123.4 Psi T Suction SP 123.4 Psi T OPN Discharge SP 123.4 Psi V13 OPN
T T T1 RUN V5 OT 50.0 T1 Tank Level %
CLS
V6 T T OPN CLS
T T CLS T OPN
V4
V15 T
OPN
V3
T T V2
OPN
OPN V14
T T
OPN
V1
V16
V17
To Station BCD
To Station DEF
Slide 34
The BP ISOM Unit HMI a Contributing Factor
No Overview No material balance (FLOW IN is No condition indication on a different graphic) No trends Essentially just a P&ID segment sprinkled with live values. Inconsistent colors and alarms
Slide 35
Level 1 Overview At-A-Glance Status
Reactor 1
Comp A Comp B
Run Plan: Actual:
Cool CPC CRM LVL
Hydrog A
Prod: Thionite State: Mid-Run Agit: ON Locks: CLEAR Balance
IN OUT
Key Performance Indicators
Bed A1 Bed A2
Cycle Comp A
Suct Dsch
Conversion Efficiency
80
%
500
80.0
Rate
72.0 2 HR VIB: BRG: OIL: Locks: OK OK OK CLEAR
F L O W
470 2 HR
70
12 HR
Emissions Limit Ratio
1.0
Reactor 2
Comp A Comp B
Run Plan: Actual:
Hydrog B
2
CRM LVL
Cool
CPC
Prod: State: Agit: Locks:
IN
CRM-114 Mid-Run ON CLEAR
OUT
Cycle Comp B
Suct Dsch
Bed B1
Bed B2
0.5
12 HR
Balance 500 68.0
Feed System
Feed A Feed B Feed C SynG
Aux Systems
CWT CWP S10 S200
Rate
60.0 2 HR VIB: BRG: OIL: Locks: OK OK OK CLEAR
F L O W
470 2 HR
Atv 1 Atv 2 Pres %IP PWR VentP VentT MGA
Alarms: ACK UNACK
P1 0 0
P2 1 0
P3 2 1
P4 4 1
Toggle List /Summary
Main Menu
Reactor 1
Reactor 2
Hydrog A
Hydrog B
Clr T-In T-Out Visc C57D Null-A Jup2 Grok
2 071608 08:55:07 RX2 LOW CRM QUALITY EXC
Trend Control
Feed Sys
Aux Sys
Menus L2 L3 L4
Slide 36
Level 2 Process Unit Control
Feed Components: A - B - C
Main Feed P 76.8 MPH S 76.0 O 88.5 % AUTO 80.0 Main Feed MPH
Reactor M5 40.0
Agitator ON
VENT SYS M5 Pressure P 98.0 psig S 95.0 O 44.3 % AUTO
Product: Thionite
State:
Mid-Run
Material Balance
Analysis: Purity %
SHUT DOWN M5
Reset IN OUT +10%
+/- 5 psi, 2hr
32.0 72.0 Additive 1 P 11.9 MPH S 12.0 O 22.3 % AUTO 14.0 Additive 1 MPH 6.0 -90 -60 -30 2 Hours
-90
-60
-30 2 Hours
+/- 1 %, 2hr
FREEZE M5
-10%
Analysis: Inhibitor Concentration % M5 Level % P 71.0 % S 70.0 O 54.3 % AUTO
ISOLATE M5
19301 Calc Diff: 2.1 %
Hours: 238.1 Since: 06/02/07 14:00:00
19707
4.0
-90
-60
-30 2 Hours 5.0 %
Run Plan: Actual:
92.0 MPH 52.3 %
PRODUCT
10.0 Additive 2 P 4.0 MPH 4.0 S O 44.3 % AUTO 6.0
Hours -90 -60 -30 2 Pumps Pump 1 Diagnostics Pump 2 Needed 1 RUNNING 1-OK 2-BAD STOPPED 4 To Coils M5 Temp P 45.0 C S 45.0 O 54.3 % AUTO 48.0 Temperature C
Additive 2 MPH
Coolant Flow
2.0
-90
-60
-30 2 Hours
Purge Cat. Rate Activity Coolant Conversion Reserve Temp Efficiency Capacity
COOLING SYS
40.0
-90
-60
-30 2 Hours
Main Menu
Level 1 Reaction Overview
M4
M6
Trend Control
Feed System
Product Recovery
M5 Startup Overlay
M5 Sequence Overlay
- Level 3 M5 Interlocks
Slide 37
- Level 3 M5 Cooling System
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
Slide 38
Summary
Poor HMIs have been cited as contributing factors to incidents and accidents Poor HMI practices are common Proper HMIs are an important success factor A High Performance HMI is practical and achievable.
???
???
???
???
???
You can:
ASSESS and BENCHMARK your HMI Do a GAP ANALYSIS for Improvement DESIGN, CREATE, and IMPLEMENT a
High Performance HMI
Slide 39
Questions?
Any Questions?
Bill Hollifield ([email protected]) www.pas.com (281) 286-6565
Slide 40
