7/24/2019 Automating Procedures
1/38
AutomatingProceduresin
ApplicationsusingISA106
Dave
EmersonDirector, Leila
MyersConsultingEngineer
U.S.DevelopmentCenter
Yokogawa
USMK
Yokogawa
SUSTAINABILITY&ECOEFFICIENCYLEANMETRICS&PERFORMANCEMANAGEMENT
INFORMATIONINTEGRATION SAFETYASSETPERFORMANCEMANAGEMENTB2MML
QUALITY&COMPLIANCEPRODUCTLIFECYCLEMANAGEMENTAUTOMATION
Do
you
knowMESA
?
7/24/2019 Automating Procedures
2/38
Todays
Goals Provideanoverviewofcurrentstandardization
activitiesregarding
automated
procedures
Explainhowyoucangetstarted
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational
7/24/2019 Automating Procedures
3/38
Agenda AutomatedProceduresIntroduction DaveEmerson
ISA106Standards
Committee
BenefitProposition
xamp es
ISA106TechnicalReportConcepts
ModularProceduralAutomation(MPA) LeilaMyers WhatisMPA?
Consultin Methodolo
Howto
select
the
right
tool
for
the
job
Exapilotexamples
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational
7/24/2019 Automating Procedures
4/38
Historical
Perspective
(1
of
3) Overthecourseofthecontinuousprocessindustryslife
procedures
Intheearlydaysoperationwasmanual Alloperationsdoneinthefield
Lotsof
people
required,
few
valves
per
person
Proceduresused,maynotofbeenwritten
st
theoperator
Lessfieldworkrequired,oratleastlessclimbing!
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational
7/24/2019 Automating Procedures
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
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational
7/24/2019 Automating Procedures
6/38
Historical
Perspective
(3
of
3) ComputerbasedcontrolsystemsDistributedControl
Control morepiecesofprocessequipmentaremergedintolargerand
Additionallayersofabstractiontakesplace
u , nmos con nuousprocessp an sopera orss performmostproceduresmanually Complexprocedures
Startingadistillation
column
Repetitiveprocedurestheoperatoraddslittlevalueto Startingpumpsetsbycontrollingindividualvaluesandpump
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational
7/24/2019 Automating Procedures
7/38
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
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational
7/24/2019 Automating Procedures
8/38
ISA
106 ISAstandardscommittee
Creatingastandard
ProcedureAutomationforContinuousProcesspera ons
Membership
,Suppliers,Consultants
Opento
any
interestedpersonor
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational
7/24/2019 Automating Procedures
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
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational
7/24/2019 Automating Procedures
10/38
CommitteeWorkItems
RecentlycompletedthefirstofthreeTechnical
ReportsTR#1ProcedureAutomationforContinuousProcess
Operations Modelsand
Terminology
TR#3 AutomatedProcedureLifecycle
an ar
w
epro uce
ase
upon
eTechnicalReportsandindustryfeedback
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational
7/24/2019 Automating Procedures
11/38
BenefitProposition
Automatingprocedures
Improvesbusiness
results
Reducesrisk feweroperationalerrors
Ensurescompliance
Studieshave
shown
that
procedure
errors
are
a
primarycauseofmanyincidents
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational
7/24/2019 Automating Procedures
12/38
ProceduralOperations
ALLprocessoperationsinALLindustrieshave
proceduraloperations
Normal,safeoperation
Changeofstatee.g.Startup,Shutdown,Transition
Proceduresmay
be:
OperatorKnowledge(Triballore)
ManualviaWrittenSOPs
SemiAutomated
Automated
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational
7/24/2019 Automating Procedures
13/38
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
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational
7/24/2019 Automating Procedures
14/38
TypicalTargetsforAutomated
Refining
Regeneration Petrochemical
Startup/Shutdown
TransitionManagement GradeChanges
LineSwitchover
Cleaning
Polymers Gradechan e
Switchover
Furnaces
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational
7/24/2019 Automating Procedures
15/38
Refinery TransitionAutomation
Opportunitytoautomateafeedswitch
Operatorworkload
reduced
by
60%
A42%reductioninproductyieldloss
ncrease ee roug pu ur ng rans on y
Reducedfeedswitchtransitiontimeby36%
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational
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
7/24/2019 Automating Procedures
16/38
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
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational
NPRA2011: AM1167NewDevelopmentsandBestPracticesinAutomatingProceduralOperationsforContinuous
Processes
7/24/2019 Automating Procedures
17/38
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
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational
7/24/2019 Automating Procedures
18/38
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
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational
7/24/2019 Automating Procedures
19/38
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
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational
ac em n emo e can ave
procedures
7/24/2019 Automating Procedures
20/38
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
EnterprisePlant Area
Plant Plant Complex Package Mill
PlantArea Area Plant
EnterpriseUnit
Equipment Equipment
Equipment
EnterpriseDevice
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational
Device Device Device
7/24/2019 Automating Procedures
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
EnterprisePlant Area
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
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational
DeviceValve
Transmitter Pump Analyzer
7/24/2019 Automating Procedures
22/38
EthyleneFurnaceExample
PlantArea
Unit
Furnace 1 Furnace 2
Furnace 5Furnace 4Furnace 3
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational
7/24/2019 Automating Procedures
23/38
EthyleneFurnaceExample
PlantArea
Discharge
Unit QUENCHTOWER
EquipmentDECOKEDRUM
Air & Fuel Input
Device
Heater
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational
7/24/2019 Automating Procedures
24/38
ProcedureRequirementsModelEnterprise
Procedure
Requirements
Enter riseSite
Proceduresareassociatedwithobjectsin
Procedure
Requirements
EnterprisePlant
Procedure
Mostcommon
for
units,
equipment
and
devicesequ remen s
EnterprisePlant Area
Procedure
Requirements
Definitionoftheprocedure
Whatmust
be
done
to
accomplish
its
EnterpriseUnit
Procedure
Requirements
objective
Functionalrequirementfortheautomatedn erpr se
ProcedureRequirements
EnterpriseDevice
proce ure
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational
Requirements
7/24/2019 Automating Procedures
25/38
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
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational
7/24/2019 Automating Procedures
26/38
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
NotificationsCommands
Human Actions
Modules
Control
Implementation
Modules
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational
7/24/2019 Automating Procedures
27/38
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)
NotificationsCommands
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational
7/24/2019 Automating Procedures
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
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational
Command Perform Verify
7/24/2019 Automating Procedures
29/38
ImplementationModuleExecution
Threeworkitemsaretypicallyusedfor
implementation
module
execution:Command Thetriggertoinitiatetheimplementation
module. Whenreceivedthiscausesthe
implementationmoduletoperformitstasks.
modulestasks.
taskswere
performed
successfully
or
failed.
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational
7/24/2019 Automating Procedures
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
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational
7/24/2019 Automating Procedures
31/38
7/24/2019 Automating Procedures
32/38
OperatorNotifications
OperatorOperatormightneedtobe
totakeanaction awarebutisnotrequiredto
takeaction
Arisesfromanabnormal
processorequipment
situation(ISA
18.2)
Alarm Alert
Arisesfromanormal
situation ISA106 Prompt StatusNotification
ISA106hasworkedwithISA18.2
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational
whichhaspublishedanalarmmanagementstandard
7/24/2019 Automating Procedures
33/38
StatebasedControl
Aplantautomationcontroldesigntechniquethat
assignsprocessstatesanddefinedtransition
procedures
Mosteffectiveattheunitlevel
Provides
a
high
degree
of
automation Startup,Shutdown,Transitions,AbnormalSituation
Responses
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational
St t b d
7/24/2019 Automating Procedures
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)
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational
Shutting Down
Mode of Operation Controlled Shutdown ProcedureShutting Down
7/24/2019 Automating Procedures
35/38
ControlSystemArchitectureManualProcedures
BasicProcess
ControlSystem AdvisoryComputer HumanMachine
InterfaceProcedure
Implementation
Modules
Inputs Outputson ro er
Procedure
Implementation
Modules
SafetyInstrumentedSystem
Auxiliarycontrolsystem
(PLC,compressorcontrol,skid,
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational
robot,vision,)
7/24/2019 Automating Procedures
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
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational
EnterpriseDevice
EnterpriseDevice
Procedure
Requirements
Control
Implementation
Modules
7/24/2019 Automating Procedures
37/38
Part1Summary
Automatedproceduresincontinuousprocess
operationscanhelpmakeaplantsafer&more
competitive
Automatedproceduresarenotwidelyusedtoday
Greatopportunity
for
improvement
ISA106isopentoallinterestedparties
ISAmembershipisnotrequired
TR#1
is
the
first
step
Weneedmoreindustr in ut
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational
7/24/2019 Automating Procedures
38/38
ThepowerofknowingwhatMESAKNOWSCopyright2012,MESAInternational