IN22 SyTech, TheReportCompany · The explosion, fire and sinking of the rig were responsible for 11 workers killed and 17 injured, The rig left more than 60,000 barrels of oil spilling

PUBLICPUBLIC Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved. 2018 Rockwell Automation TechED™ Event #ROKTechED

IN22 SyTech, TheReportCompany.comOptimize Data From FactoryTalk Alarms and Events To Improve Performance

Presenter Name, Peter V. KaprielianPresenter Title, CTO2pm 11th June 2018, 9am 13th June 2018

✓ SyTech: The Company

✓ XLReporter: The Product

✓ Evolution of Alarm Management

✓ Alarm Management Standards

✓ XLReporter Alarm Module

IN22 - Session Content

Copyright © SyTech, Inc. 2018, All rights reserved.

XLReporter Is Industrial ReportingSoftware for Process Automation

✓ About SyTech▪ Founded in 1994

▪ Headquartered in Massachusetts USA

▪ Encompass partner since 2001

▪ Develop and Support XLReporter▪ Reporting Software for Industry

✓ XLReporter Used By … for▪ Water and Wastewater … Compliance

▪ Energy Management … Performance

▪ Automotive … Operational

▪ Oil and Gas … Production

▪ and more …

SyTech


✓ “Out of Box” Software▪ No Scripting/SQL/Programming▪ No Limits, Tags, Reports or Templates

✓ Designed for Industrial Automation▪ Award winning

o Two-time winner of Control Engineering Award

▪ Small footprint o Use on existing hardware and OS

✓ Utilize Existing Skills▪ Design Workbook Templates

o No Limitso Need a tip? Over 1B users of Excel or 1 in 7 people!

✓ Report, Reliably, 24x7▪ Produce Workbook, PDF and Web Pages▪ No additional software to produce or view reports

o XLReporter uses the Microsoft Open XML standard

✓ Scalable▪ Start small and grow

XLReporter Is Industrial Reporting

Connect Design Produce DistributeCopyright © SyTech, Inc. 2018, All rights reserved.

✓ Connectivity▪ Over 70 connectors.

o No Limits

o Real time, historical and relational databaseso OPC, ODBC, OLE DB

✓ Industry Analytics▪ Standard Calculations

o Minimum, Maximum and Average (for each day of month)

▪ Industry Specific Calculationso How many times did the pumps cycle

o How efficiently is equipment utilized

o What are the top 5 occurring alarms

▪ Scaling, Filtering

✓ Report Automatically or On-Demand▪ Schedule tasks on Time or Event

o End of each shift, batch end

▪ Schedule tasks on Evento Cycle End

Industry analytics From Raw Data

Industrial Components


Industrial Features

Bitmaps and Icons

Tabular/Free Format Content

Conditional Formatting

Charts


Custom Report Names

Industrial Calculations

“Report As You Run” Technology

Excel/XLR Functions

Connectors for Rockwell AutomationP

lant F

loor

To B

ack O

ffic

e

PLCs

For Any BudgetFrom $995

FT View SE

Panel View Plus

FT View ME

Data Logger (eWon)

FT Historian SE

XLReporter Analytics

Manual Data Entry

FT View SE

Data Logs

FT Historian ClassicFT Alarm/Event

No LimitsTags, Templates,

Reports

Relational Database

Data SourcesReal time Historical Relational


Session FocusP

lant F

loor

To B

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FT Alarm/Event

Data SourcesReal time Historical Relational


✓ Mimic Panels▪ Hard Wired▪ Expensive▪ Required Space

✓ Alarm Management▪ Very Effective▪ Careful Alarm Selection▪ Plenty Of Discussion▪ Documentation


Alarms In the 70’s


✓ The Digital Era▪ Mimic Panels Became Obsolete▪ Adding Alarms Became Cheap▪ Information on Computers

▪ Visibility Restrictions

✓ Alarm Management▪ Setup Was Easy, Far Too Easy▪ Documentation Took A Backseat

Alarms In the 80’s


Alarm Flood!✓ Waste Water Treatment Plant

▪ 2:12 am - several critical alarms flooded the main control room and indicated the plant’s process has broken down and pumps had stopped. The following quote is directly from the operator “Alarms within …. A matter of minutes, a ton of them”

▪ 2:21 am - two alarms triggered by a bubbler, hit high-high on the operator's display, showing the two primary tanks were dangerously close to overflowing, however, the operator didn’t see them. Four minutes later two more alarms showed the tanks were past capacity.

▪ 2:25 am - wastewater began flooding the plant

235 million gallons of untreated wastewater and 30 million gallons of raw sewage released into Puget Sound.

Damage > $25 million


Alarm Suppression!✓ Deepwater Horizon Oil Rig

▪ On April 20, 2010, a surge of natural gas went undetected causing an explosion on the Deepwater Horizon offshore oil rig

▪ From the Washington Post on July 23, 2010, Michael Williams, a chief engineer on the Deepwater Horizon Rig told a federal panel that he understood the rig had been operating with the gas alarm system in “inhibited” mode for a year to prevent false alarms from disturbing the crew.

The explosion, fire and sinking of the rig were responsible for 11 workers killed and 17 injured, The rig left more than 60,000 barrels of oil spilling into the Gulf of Mexico for a total of approximately 5 Million barrels in total.

Damage > $60 billion and manslaughter charges


EEMUA-191

ISA-18.2

IEC-62682

Industry Standards

1999 2009 2014Copyright © SyTech, Inc. 2018, All rights reserved.

ISA 18.2 provides requirements and recommendations for the activities of

the alarm management life cycle. It was reaffirmed globally with the

release of IEC-62682

What is an Alarm

✓ ISA 18.2 Definition

▪ “an alarm is an audible and/or visible means of

indicating to the operator an equipment malfunction,

process deviation, or abnormal condition requires a

response”


Action Required Information

Abnormal Alarm Alert

Expected Prompt Message

Key Design Principles

✓ Every alarm should have a defined response

✓ Adequate time should be allowed for the operator to carry out the defined response

✓ Every alarm presented to the operator should be useful, relevant and unique

✓ Operators should not get overwhelmed with alarms

✓ Alarms should be prioritized and understandable


If the Operator

Response (Action)

Cannot Be Defined

then it is Not an Alarm

- EEMUA 191 (2013)

ISA-18.2, IEC-62682

✓ Alarm Philosophy

▪ Objectives, guidelines and work processes

✓ Alarm Rationalization

▪ Identify alarms and their priorities

▪ Consequences of no action

✓ Implementation

▪ Configuration of the rationalization results

✓ Monitoring and Assessment

▪ Measure performance regularly


Alarm Management Life Cycle

✓ Encompass Partnership▪ Collaborative Effort

✓ exida▪ Consulting Services

▪ PR016 Alarm Management

✓ SyTech▪ Reporting Services and Software

▪ Benchmark Assessment Report

▪ Monitor and Report


Performance Indicators


Average Alarm Rate per day

Average Alarm Rate per hour

Average Alarm Rate per 10 min

Alarm Priority Distribution

% of Time with >10 Alarms per 10 min

Maximum Alarms in a 10 min Period

% of Time with >30 Alarms per hour

% of Time in Alarm Flood Condition

Number of Stale Alarms

% of the Top 10 Active Alarms

Number of Chattering Alarms

Average Alarm Rateper hour in Flood

Average Alarm Rateper hour excl. Flood

Alarm Priority Timeline

Performance Targets


Performance Indicator Target

Average Alarm Rate per day 150 - 300

Average Alarm Rate per hour 6 - 12

Average Alarm Rate per 10 minutes 1 - 2

Percentage of 10 mins periods > 10 alarms < 1%

Maximum Alarms in a 10 minute Period <= 10

Percentage of Time in Alarm Flood Condition < 1%

Percentage of the Top 10 Alarms < 1% to 5%

Number of Chattering/Fleeting Alarms 0

Number of State Alarms < 5

Priority Distribution (Low) ~ 80%

Priority Distribution (Medium) ~ 15%

Priority Distribution (High) ~ 5%

Top 10 Alarm Contribution


The percentage of alarms coming from the top-ten most frequent alarm sources relative to the total alarm count.

✓ Contributors▪ Nuisance Alarms (which tend to get ignored over time)

▪ Misuse of the Alarm System

Top Ten Alarms create 32% of

notifications!

Average Alarm Rate


Average alarm rate is the measure of the frequency with which new alarms are presented to the operator, expressed as an average count.

✓ Contributors▪ Events that are not Alarms

▪ Chattering/Fleeting Alarms

▪ Cascading Alarms

Alarm Timeline

Distribution over each day

of the reporting period

Distribution over each

hour of the day of

maximum activity


Identifying “Bad Actors”

Top Ten Alarms create 32% of

notifications!


Alarm Floods


Alarm Flood can be defined as beginning when the alarm rate exceeds more than 10 alarms in 10 mins and ending when the rate drops below 5 alarms in 10 mins

✓ Contributors▪ Alarms for the Same Abnormal Condition

▪ Cascading Alarms

▪ Poor Control Design

Identifying Alarm Floods

Multiple Flood scenarios

Floods last a long

period of time


Chattering Alarms


Chattering alarms are alarms that repeatedly transition between alarm state and normal state in a short period of time. Most common measure is 3 alarms in 1 minute.

✓ Contributors▪ Insufficient hysteresis (deadband)

▪ No on/off delays

Two alarms contribute to

over 50% of chattering

Stale Alarms


A stale alarm is one that remains annunciated for an extended period of time, most often specified as 24 hours. Challenging to measure and difficult to remove.

✓ Contributors▪ Standby or idle equipment

▪ Alarms no longer relevant

▪ Alarms latched due to excessive hysteresis

▪ Alarms outside the operators control, waiting for maintenance

Identifying Stale Alarms

Alarm Active Time

D:H:M:S


Benchmark


Benchmark Assessment Report✓ Free to Eligible Users

▪ Users Provides Data (15-30 days)

▪ Report Returned at No Cost

✓ Purpose▪ Provide a Benchmark

▪ Help Justify Investment

✓ Subscription or Installation▪ Subscribe to Periodic Reports

▪ User Provides Data

▪ XLReporter with Alarm Module▪ Install on premises


Monitoring and Assessment


Monitoring and Assessment


✓ Plant View of Alarm Performance

✓ Alarm KPI Metrics

✓ Alarm Report Includes▪ “bad actors”

▪ nuisance alarms

▪ alarm floods

▪ frequency

✓ Alarm Priority Distribution▪ Calculated using ISA recommendations

Monitoring and Assessment✓ Based on ISA 18.2

✓ KPI Dashboards

✓ Drill Down to Details

✓ Scheduled and On-Demand

✓ Customize to Needs

✓ Combine with Process Data

✓ Automated Report Distribution


✓ Add Process Metrics and KPIs▪ Uptime/Downtime starts/stops e.g., OEE

✓ Export to Back Office▪ Produce XML, CSV from worksheet

▪ Quality Control.

Report Automatically


Report On Demand

Template Selection.

Alarm/Process/History

Filter Selection.

Date/Position/Area

Distribute.

Workbook/PDF

Email/Printer

Report Tabs.


✓ Web Portal▪ Open from any browser.

▪ No Access Limits

✓ Auto Update

✓ Email, FTP, Printer▪ Mobile, Email, Text Message

o Dynamic/Compressed attachments

o Live values in content

Publish to Web Portal


✓ Publishing Methods▪ Automatically

▪ Manual “Dropbox”

✓ Hyperlinks▪ Trends

Publish to VantagePoint

Links to VP

Trends


Automatically Add

Content

Benefits of Alarm Management✓ Increased Uptime and Production

▪ Studies show 3-8% losses due to abnormal situations

✓ Regulatory Compliance▪ GAAP

✓ Insight Into Emerging Problems▪ Tuning

✓ Incident Prevention▪ Reduce chance to miss critical alarms.

✓ Improved Productivity▪ Reduce Alarm Load on Operator

▪ Remove nuisance alarms

Copyright © SyTech, Inc. 2000-2018

Awards and Testimonials

“The automation interface provided by SyTech enables Excel to be used in more niche markets that require automated and unattended operation. This is an example of how Microsoft Office applications can solve critical business problems for our customers and deliver great benefits from creative partners like SyTech.”

Microsoft Corp.

XLReporter is a two-time winner of Control Engineering Choice Award

Copyright © SyTech, Inc. 2000-2018

Information and Download

✓ Show

▪ Evaluation CDs at Booth

▪ Daily Amazon Gift Card Giveaway

✓ Web

▪ www.SyTech.com

▪ www.TheReportCompany.com

✓ Email

▪ [email protected]

✓ Phone

▪ 508 520 9957 (9XLR)

41Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved. 2018 Rockwell Automation TechED™ Event #ROKTechEDPUBLIC

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IN22 SyTech, TheReportCompany · The explosion, fire and sinking of the rig were responsible for 11 workers killed and 17 injured, The rig left more than 60,000 barrels of oil spilling