automating procedures

7/24/2019 Automating Procedures

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AutomatingProceduresin

ApplicationsusingISA106

Dave

EmersonDirector, Leila

MyersConsultingEngineer

U.S.DevelopmentCenter

Yokogawa

USMK

Yokogawa

SUSTAINABILITY&ECOEFFICIENCYLEANMETRICS&PERFORMANCEMANAGEMENT

INFORMATIONINTEGRATION SAFETYASSETPERFORMANCEMANAGEMENTB2MML

QUALITY&COMPLIANCEPRODUCTLIFECYCLEMANAGEMENTAUTOMATION

Do

you

knowMESA

?


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Todays

Goals Provideanoverviewofcurrentstandardization

activitiesregarding

automated

procedures

Explainhowyoucangetstarted

ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational


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Agenda AutomatedProceduresIntroduction DaveEmerson

ISA106Standards

Committee

BenefitProposition

xamp es

ISA106TechnicalReportConcepts

ModularProceduralAutomation(MPA) LeilaMyers WhatisMPA?

Consultin Methodolo

Howto

select

the

right

tool

for

the

job

Exapilotexamples



4/38

Historical

Perspective

(1

of

3) Overthecourseofthecontinuousprocessindustryslife

procedures

Intheearlydaysoperationwasmanual Alloperationsdoneinthefield

Lotsof

people

required,

few

valves

per

person

Proceduresused,maynotofbeenwritten

st

theoperator

Lessfieldworkrequired,oratleastlessclimbing!



5/38

Historical

Perspective

(2

of

3) Remoteactuatorsonvalvesintroduced

Operatorscould

manage

larger

parts

of

the

process

Fewerfieldoperators

PIDcontrollers

removed

o erators

from

the

loo

Operatorsnowsupervisedloops,nolongerperformed

control

Operatorscould

manager

larger

parts

of

the

process



6/38

Historical

Perspective

(3

of

3) ComputerbasedcontrolsystemsDistributedControl

Control morepiecesofprocessequipmentaremergedintolargerand

Additionallayersofabstractiontakesplace

u , nmos con nuousprocessp an sopera orss performmostproceduresmanually Complexprocedures

Startingadistillation

column

Repetitiveprocedurestheoperatoraddslittlevalueto Startingpumpsetsbycontrollingindividualvaluesandpump



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Why

Not

Just

Use

ISA

88? Inthe17yearssinceISA88hasbeenastandardithasbeen

individual

basis

in

the

continuous

process

industries Whenusedforcontinuousprocessestweakshadtobemade,sonotaperfectfit

Continuousprocesseshavedifferentcharacteristicsfrombatch Ingredientsnottreatedthesame

Manydifferent

procedures

used,

not

always

tied

in

anice

recipe

Equipmentindependencenotasignificantfactor

Nosignificantadoption,Timeforsomethingdifferent

discuss

and

standardize

procedure

automation

holistically

Goal:Makeprocedureautomationanexpectedpartofanycapitalproject



8/38

ISA

106 ISAstandardscommittee

Creatingastandard

ProcedureAutomationforContinuousProcesspera ons

Membership

,Suppliers,Consultants

Opento

any

interestedpersonor



9/38

Membership

(partial) ABB

Honeywell

AREVA BayerMaterialScience

BPLubricants

Invensys MustangAutomationandControl

NovaTech ProcessSolutions

Braskem

CDMSmith

CH2MHILL

PAS

Prosys

RockwellAutomation

Chevron

Conocophillips

DSMCorporateOperations

RSISimcon

SaudiAramco

SavannahRiverNuclearSolutions

u o EmersonProcessManagement

ExxonMobil

TheDowChemicalCompany

ValeroEnergyCorp



10/38

CommitteeWorkItems

RecentlycompletedthefirstofthreeTechnical

ReportsTR#1ProcedureAutomationforContinuousProcess

Operations Modelsand

Terminology

TR#3 AutomatedProcedureLifecycle

an ar

w

epro uce

ase

upon

eTechnicalReportsandindustryfeedback



11/38

BenefitProposition

Automatingprocedures

Improvesbusiness

results

Reducesrisk feweroperationalerrors

Ensurescompliance

Studieshave

shown

that

procedure

errors

are

a

primarycauseofmanyincidents



12/38

ProceduralOperations

ALLprocessoperationsinALLindustrieshave

proceduraloperations

Normal,safeoperation

Changeofstatee.g.Startup,Shutdown,Transition

Proceduresmay

be:

OperatorKnowledge(Triballore)

ManualviaWrittenSOPs

SemiAutomated

Automated



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RefineryIncidentsFAT/CATs

KernOilRefineryinBakersfield,CaliforniaonJanuary19,2005

nc ent e oneemp oyeean cause mu t p e n ur estoot er

employees Crudeunitstartup

Workersoverpressurizedapumpcasingwhichcatastrophicallyruptured,releasingandignitinghotoilthatimmediatelyexploded

GiantIndustries

Ciniza Refinery,

Gallup,

New

Mexico,

April

8,

4

6employeeswereinjured,4requiringhospitalizationwithseriousburninjuries

Duringhydrofluoric

acid

(HF)

alkylation

unit

maintenance

ashut

off

valvewasnotclosedasrequired,causedreleaseofflammableliquidsandvaporswhichcausedsubsequentexplosions



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TypicalTargetsforAutomated

Refining

Regeneration Petrochemical

Startup/Shutdown

TransitionManagement GradeChanges

LineSwitchover

Cleaning

Polymers Gradechan e

Switchover

Furnaces



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Refinery TransitionAutomation

Opportunitytoautomateafeedswitch

Operatorworkload

reduced

by

60%

A42%reductioninproductyieldloss

ncrease ee roug pu ur ng rans on y

Reducedfeedswitchtransitiontimeby36%


Console Operator Moves per Hour Comparison from paper Improving Refinery Unit Transitions Using Process Automation Technology

in a base Oil Hydroprocessing Facility. AIChE Spring 2011 Robert M. Tsai, Chevron, Richmond, CA


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AcrylicAcidProduction

Start-up time to

steady state was

reduced by 30%

Less variability in

start-u time

4

5

manual

automated

Reactors able to

come on stream

70% faster

Averag e valu e manual

3

rtup

duration

[h]

about 30 %

Average value aut omated

Process safety

margins, of1

2Sta

during startup,

were significantly

increased

01 2 3 4 5 6 7 8 9 10 11

Start up process No.

12 13 14 15 16 17


NPRA2011: AM1167NewDevelopmentsandBestPracticesinAutomatingProceduralOperationsforContinuous

Processes


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BenefitsDerivedfrom

Improvedsafety ImprovedOperator

per ormance

Improvedreliability

Moreconsistento eration

ect veness

Automatedprocedures

Reducedlosses

Feweroperator

errors

operator

Knowledgecapture

Improvedresponsesto

disturbances

IncreasedProduction

Improvedtraining

Improvedinsightintothe

rocess Faster

&

more

consistent

startupsandshutdowns

Moreefficienttransitions

Designprocesscanimproveprocedures



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ModelsandTerminology

1stTechnicalReport

Statescommittees

current

thinking

on

how

to

organizeandapproachprocedureautomation

Models

Conceptsto

give

the

industry

acommon

mental

modelforautomatedprocedures

Terminology

Definitionsto

give

the

industry

acommon

language

forautomatedprocedures



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PhysicalModel

Organizesphysicalequipmentintoa

Enterprise

EnterpriseSite

Providesacommon

set

of

terms

and

Enterprise

Plant

industriestomaptheirtermsto

Commonterms

enable

roducts

and

eo le

to

EnterprisePlant Area

workmoreefficientlywithdifferent

owner/operators.

EnterpriseUnit

P ysica

mo e

ist e

oun ation

o

t e

ISA106workEquipment

EnterpriseDevice


ac em n emo e can ave

procedures


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PhysicalModelToday

Results of committee owner/operator terminology

Enterprise

EnterpriseSite

ISA106 ChemicalCompany

OilRefinery Offshore

Oil

Platform

Example1

Offshore

Oil

Platform

Example2

Paper

IndustryEnterprisePlant

Enterprise Enterprise Field

Site Site Site Platform Platform


Plant Plant Complex Package Mill

PlantArea Area Plant

EnterpriseUnit

Equipment Equipment

Equipment

EnterpriseDevice


Device Device Device


21/38

PhysicalModelExamples

Results of committee owner/operator terminology

Enterprise

EnterpriseSite

Enterprise Corporate Division

Business

Unit

Site Complex Train Facility Verbund Field

EnterprisePlant

Plant Platform Train

Separation Train Subsea

Gas

Compression Dehydration


PlantAreaInjection Utilities

Water

Treating Production

Manifold

Wells

Unit Separator Dry/WetOil Pipeline

Hydrocyclone Compressor

EnterpriseUnit

an s umps

Equipment PumpSet Feed System Reboiler Sampling

System Compressor

Equipment

EnterpriseDevice


DeviceValve

Transmitter Pump Analyzer


22/38

EthyleneFurnaceExample

PlantArea

Unit

Furnace 1 Furnace 2

Furnace 5Furnace 4Furnace 3



23/38

EthyleneFurnaceExample

PlantArea

Discharge

Unit QUENCHTOWER

EquipmentDECOKEDRUM

Air & Fuel Input

Device

Heater



24/38

ProcedureRequirementsModelEnterprise

Procedure

Requirements

Enter riseSite

Proceduresareassociatedwithobjectsin

Procedure

Requirements

EnterprisePlant

Procedure

Mostcommon

for

units,

equipment

and

devicesequ remen s


Procedure

Requirements

Definitionoftheprocedure

Whatmust

be

done

to

accomplish

its

EnterpriseUnit

Procedure

Requirements

objective

Functionalrequirementfortheautomatedn erpr se

ProcedureRequirements

EnterpriseDevice

proce ure


Requirements


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ProcedureImplementationModel

Site Implementation

Modules

Theactualautomatedprocedure

PlantImplementation

Modules

rogram, unc on oc ,sequen a unc on

chart,flowchart,

Plant Area

Implementation

Modules

Unit

engineeringprocess

Procedurerequirements

are

the

specification

Implementation

Modules

Equipment

Implementation

Notalwaysa1:1mappingwithprocedure

requirements

Modules

Control

Implementation

Modules



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ImplementationModules

ConsistofasetoforderedtasksSite ImplementationModules

as smaycon a n as s

Tasksperform

step

by

step

actions

PlantImplementation

Modules

NotificationsCommands

Plant Area

Implementation

Modules

Unit

Peer to

PeerHuman

Interface

Programming

Continuous

Control

Implementation

Modules

Equipment

ImplementationCommands

andNotifications


Human Actions

Modules

Control

Implementation

Modules



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ImplementationModules

Implementationmethodsareanytypeoftoolusedtocreatea

tas .

Programming

ContinuousControl

HumanActions.

Examples

of

programming

types

Peer to

Tasks

Programming

omputerprograms

Configurablefunctionblocks

ContinuouscontrolfunctionsCommands

and

Notifications

PeerHuman

InterfaceContinuous

Control

Human Actions

Executableflowcharts.

ProcedureFunctionCharts(PFC)




28/38

ProcedureExecution

EachProcedure,Implementation

Module & Task has 3 execution workProcedure

items

Command TriggerImplementation Module

Verify Success/Failure

Computer/HumanMix

. . .

CPVworkitemscanbedoneby

acomputerorhuman

Task Task Task Task


Command Perform Verify


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ImplementationModuleExecution

Threeworkitemsaretypicallyusedfor

implementation

module

execution:Command Thetriggertoinitiatetheimplementation

module. Whenreceivedthiscausesthe

implementationmoduletoperformitstasks.

modulestasks.

taskswere

performed

successfully

or

failed.



30/38

AutomationStyles

Organizationofthestructureofthe

implementation

module

such

as

using

procedure

sectionsorprocessstates

Useofcomputeroroperatoractionfor

command,perform,

verify

Amountofprecisionusedforverification

Humanmachineinterface hiloso h

Degreeof

automation

from

minimal

automation

tocom lexautomation



31/38


32/38

OperatorNotifications

OperatorOperatormightneedtobe

totakeanaction awarebutisnotrequiredto

takeaction

Arisesfromanabnormal

processorequipment

situation(ISA

18.2)

Alarm Alert

Arisesfromanormal

situation ISA106 Prompt StatusNotification

ISA106hasworkedwithISA18.2


whichhaspublishedanalarmmanagementstandard


33/38

StatebasedControl

Aplantautomationcontroldesigntechniquethat

assignsprocessstatesanddefinedtransition

procedures

Mosteffectiveattheunitlevel

Provides

a

high

degree

of

automation Startup,Shutdown,Transitions,AbnormalSituation

Responses


St t b d


34/38

Not Ready

Mode of Operation

Not Ready

(Out of Service)

State-based

Control ExamplePreparing

Mode of Operation Prepare ProcedurePreparing

Mode of Operation Procedure

Implementation Module

Task Task Task. . .

(Idle)

Filling

Startup

Mode of Operation Startup Procedure Implementation Module

Task Task Task Task

Heating

Production Rate of ChangeRunning

Mode of Operation Abnormal Condition HandlingProcedure

Abnormal

(Off Spec)


Shutting Down

Mode of Operation Controlled Shutdown ProcedureShutting Down


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ControlSystemArchitectureManualProcedures

BasicProcess

ControlSystem AdvisoryComputer HumanMachine

InterfaceProcedure

Implementation

Modules

Inputs Outputson ro er

Procedure

Implementation

Modules

SafetyInstrumentedSystem

Auxiliarycontrolsystem

(PLC,compressorcontrol,skid,


robot,vision,)


36/38

ISA106KeyModels

Physical ModelEnterprise

Procedure

Requirements Model

Enterprise

EnterpriseSite

Procedure

Requirements

EnterpriseSite

ProcedureSite

Implementation

Implementation Model

EnterprisePlant

EnterprisePlant

Procedure

Requirements

Plant

Implementation

Modules

n erpr sePlant Area

EnterpriseUnit

n erpr seProcedure

Requirements

EnterpriseUnit

Procedure

Implementation

Modules

Unit

Implementation

EnterpriseEquipment

Requirements

EnterpriseEquipment

Procedure

Requirements

Modules

Equipment

Implementation

Modules


EnterpriseDevice

EnterpriseDevice

Procedure

Requirements

Control

Implementation

Modules


37/38

Part1Summary

Automatedproceduresincontinuousprocess

operationscanhelpmakeaplantsafer&more

competitive

Automatedproceduresarenotwidelyusedtoday

Greatopportunity

for

improvement

ISA106isopentoallinterestedparties

ISAmembershipisnotrequired

TR#1

is

the

first

step

Weneedmoreindustr in ut



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automating procedures

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