2017 siemens automation exporting alarm …€¢ we are a siemens solution partner for pcs7 with 7...

EXPORTING ALARM SETPOINTS

IN SIEMENS PCS7Jared Romano, Pigler Automation

usa.siemens.com/summitUnrestricted © Siemens 2017

2017

Siemens

Automation

Summit

Unrestricted © Siemens 2017

2017 Automation Summit

Title: EXPORTING ALARM INFORMATION FROM SIEMENS PCS7

Track: Productivity & Efficiency

Presenter: Jared Romano

Company: Pigler Automation

Session #: 5.1


• Pigler Automation, LLC was founded in 2005

• We are a Siemens Solution Partner for PCS7 with 7 Siemens PCS7-Certified Engineers

• Located in Longmont, Colorado -- 30 miles north of Denver

• 10 Employees and Growing

• Industries Served: Chemical, Power and Mining, ….

For more information please visit:

www.piglerautomation.com

Or call : (866) 871-1456

http://www.piglerautomation.com/


Bio Slide

Jared Romano

• B.S. in Electrical Engineering from Colorado State University

• Engineering Intern with Pigler Automation, LLC from April 2014 to May 2015

• Process Controls Engineer with Pigler Automation, LLC since May 2015

• PCS7 Certificed Process Control Engineer


The Challenge:

The Cost of Mismanaged Alarms

Page 5

1. Honeywell Process Solutions - Alarm management and rationalization - Intelligent alarm handling rules - Aonghus Keegan

2. Honeywell Process Solutions - Uop Alarm Help Delivered Directly To Operators For Safer, More Productive Operations

Refining and Chemicals Alarms per

Operator per Day

Without Alarm Management 1350

With Alarm Management 250

Typical Cost

One missed alarm resulting in a

unplanned shutdown

$3.5M

One misunderstood alarm as a

result of operator error leading

to a loss in containment

$15M

(Impacted losses

as direct result)


Page 6

ISA 18.2 Alarm System Management

• In 2003, ISA started developing an

Alarm System Management

standard.

• In 2009 ANSI/ISA-18.2 Management

of Alarm Systems for the Process

Industries standard was published


What is Alarm Rationalization?

• A process where a cross-functional team of plant stakeholders

reviews, justifies, and documents that each alarm meets the

criteria for being an alarm as set forth in a company’s alarm

philosophy document.

• Involves defining the attributes of each alarm as well as

documenting the consequence, response time, and operator

action.

• The output of rationalization is a Master Alarm Database (also

known as an alarm catalog) containing the alarm configuration

requirements


ISA 18.2 Rationalization

ISA 18.2 defines specific requirements for alarm

rationalization:

1. Alarm type

2. Priority

3. Class

4. Alarm setpoint value or logical condition

5. Operator action

6. Consequence of Inaction or incorrect action

7. Need for advanced alarm handling techniques if

necessary

Page 8


What will we cover?

1. Strategies for developing software

to extract all alarm information

required for rationalization

2. Methods of implementing

rationalized information to improve

plant operations


How Can We See Alarm Information in PCS7?

Messages tab in Process Object view

Page 10


What Is Missing?

1. Alarm type

2. Priority

3. Class

4. Alarm setpoint value or logical condition, disable or enabled

5. Operator action


7. Need for advanced alarm handling techniques if necessary.

Page 11


Parameters Tab in Process Object View


Example: MonAnL

Considerations

• HMI Alarm messages are turned off when either PV_MSG_EN or PV_EN are disabled

• PV_Unit is often Interconnected to a Channel Driver block

• Alarm Limits can also be interconnected

• MonAnL has two ALARM8 Objects

• Block comment is inserted for the event message


Example: MEAS_MON

Considerations

• Ways to turn off HMI Alarm messages

➢ Suppression IO on MEAS_MON are set to 1

• Unit is configured at the U as a string

• MEAS_MON as only one alarm objects


Overview of Process


Expected Result


First Attempt: Excel Macro

Page 17

Problems:

Required many tabs to manage data Additional formatting required

Copy Data to Spreadsheet Messy and Complicated code

Difficult to export configuration data Slow Processing


VB.Net or C# in Visual Studio

Advantages

• Easy to design a full UI

• Provides use of data tables

o Easily export data tables to .XML configuration file

o Run SQL queries to search for setpoints – Minimizes Looping

• Quickly convert CSV exported from Process Object View to data table

using OLEDB connector

Page 18


Main Interface


Configure PCS7 Block Types

Page 20

• Use objects in a Windows form to help

organize the input data

• Important Block Parameters:

o Setpoint IO

o Alarm Enable IO

o Msg Enable IO

o Signal Identifier IO

o Unit IO

o MSG_Evid Name

• Import the data entered on the form into

a DataTable for quick querying


Configure Units and Interconnected Blocks

Page 21

• Add a unit table and blocks that define the

unit or setpoint through an interconnection

• Configured tables can be stored in .csv or

.XML format using

dataTable.WriteXML(path)


Exporting from Process Object View

• Parameters Tab - select “Export All I/O”

o Prevents the need to select individual I/O

• Messages tab, select “Export Current view…”

o Includes the Block Comment column

▪ $$BlockComment$$ needs to be replaced with the correct

text

o “Export Messages…” does not include block comment

Page 22


Coding: Importing the Data and Making Queries

• SQL queries can be made to quickly search for relevant data. NO LOOPS!

• Greatly reduces seek time

• Uses less system resources

Page 23

Note: Data gets returned as DataRow array, not a DataTable. Convert back to data table by first checking the length.

• Use an OleDb adapter to quickly import the CSV into a data table


Convert to Excel

• Closed XML is an open source library to export data tables to .xlsx

• More info: https://github.com/ClosedXML/ClosedXML/wiki

• Add additional rationalization columns and export to excel

Page 24

https://github.com/ClosedXML/ClosedXML/wiki




rationalization:

1. Alarm type

2. Priority

3. Class


5. Operator action


7. Need for advanced alarm handling techniques if

necessary.

Page 25


New with PCS7 V9.0: Alarm Help Text

Description

Possible

causes

Suggested

operator

action

Consequence


Filled out Excel


Import Modified Excel and Export to CSV

The modified Excel file can be converted back to a data table using

Closed XML.

• Full tutorials for using Closed XML can be found at

https://www.aspsnippets.com

The data table can be exported to CSV to import the data back to

PCS7

• Can be done just using a simple StreamWriter or there are open

source tool to simplify

o CSV Helper is a great .NET library for reading and writing CSV

files

o It can be imported via the Visual Studio Package Manager

Console

Page 28

https://www.aspsnippets.com/


Import to PCS7 V9.0 Process Object View

Columns that must be maintained in order for the CSV

to be imported to Messages in Process Object View

• Hierarchy

• Chart

• Block

• I/O name

• Subnumber

Page 29




rationalization:

1. Alarm type

2. Priority

3. Class


5. Operator action


7. Need for advanced alarm handling techniques

if necessary.

➢ More information can be found at the User

Community site from the 2014 Automation

Summit Presentation on Smart Alarm Hiding

Page 30


Support Operation with Voice Interaction

“Hey Alexa”


For Voice Interaction

Export to SQL

• The Data Table can also be exported to a SQL Database to allow Third party

software to query

• Anything other than SQL Server it is recommended to install a third-party

connector

• Primary Keys

o Chart

o Block

o IOname

o Subnumber (Sig_#)

Page 32


Alexa can make SQL Queries for you!

• Amazon Alexa uses hands-free voice recognition to extract relevant data from

SQL database

• Provides the operator with detailed information including the recommended

course of action

• “Alexa ….. Start Alarms”

• “TI001 high”

Page 33


What’s Next

Alarm Tool Alexa

Include an OPC connection

• Provide live data values and quickly determine if

an alarm is enabled or disabled

• Retrieve units without interconnection algorithms

Alexa notifications can be used to alert the operator of

any issues in real time as they develop. (Future

feature)

• Use OPC alarm tags to trigger Alexa to

automatically query Alarm information

Expand these concepts to create IO lists


EXPORTING ALARM SETPOINTS IN SIEMENS PCS7

Name: Jared Romano

Company: Pigler Automation

Email: [email protected]

Phone: (866) 871-1456 Ext. 8

Session #: 5.1

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2017 siemens automation exporting alarm …€¢ we are a siemens solution partner for pcs7 with 7...

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