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Best Practice for Modular Procedural Automation

(in lingua inglese)

1.Advanced Decision Support (ADS)
2.Solution Introduction – Modular Procedural Automation (MPA)
3.Enabling Technology (Exapilot)
4.Customer Benefit Success Stories

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Estratto del testo
Milano, 30 novembre 2017 Gli atti dei convegni e pi di 8.000 contenuti su www.verticale.net | May, 2017 | Yokogawa Electric Corporation The pursuit of Operational
Excellence through
Automated Procedures
Enabling solution:
Modular Procedural Automation (MPA)
Alessandro Roncarati Advanced Solution Consultant Nov, 2017 1 | May, 2017 | Yokogawa Electric Corporation Contents 1. Advanced Decision Support (ADS) 2. Solution Introduction ' Modular Procedural Automation (MPA) 3. Enabling Technology (Exapilot) 4. Customer Benefit Success Stories 5 | May, 2017 | Yokogawa Electric Corporation Visual Dictionary ' SOP = Standard Operating Procedure 6 ' MPA = Modular Procedural Automation | May, 2017 | Yokogawa Electric Corporation Advanced Decision Support (ADS) 10 | May, 2017 | Yokogawa Electric Corporation We don't want humans to do the work Why do we automate' ' Speed, efficiency, precision, repeatability ' Unacceptable risk for human life ' Humans make mistakes Humans don't want to do the work ' Too heavy, too dangerous, dull 11 | May, 2017 | Yokogawa Electric Corporation Humans still bring unique value Why do we still use humans' ' Creativity ' Adaptation ' Understanding Full auto is a myth ' Unforeseen events ' Costs C O S T S CREWSIZE Total cost of ownership Manning costs Automation costs Technology overkill Personnel overkill Optimized manning 12 | May, 2017 | Yokogawa Electric Corporation A fine balance ' Inappropriate trust in and reliance on automation ' Relevant information at the right time ' Automation induced error ' Keep the operator involved ' 'Out-of-the-loop' syndrome ' De-skilling; use it or lose it 13 | May, 2017 | Yokogawa Electric Corporation The role of the future operator Physical Labor Optimizing efficiency, production, energy Needed most during unforeseen crises Needs to make sense of many data sources Mental Effort 14 | May, 2017 | Yokogawa Electric Corporation What is Advanced Decision Support (ADS)' Alarm Management Procedure/Batch Management HMI Design Control Room Environment ADS leverages technologies to provide the operator with the right information, in the right format, at the right time to make the correct decision 15 | May, 2017 | Yokogawa Electric Corporation Procedure Management
Challenges
17 | May, 2017 | Yokogawa Electric Corporation Food for thought Have you ever driven somewhere and not remembered how you got there' 18 | May, 2017 | Yokogawa Electric Corporation What IS a procedure' Definitions ' A particular way of accomplishing something or of acting
' A series of steps followed in a regular definite order
' A set of instructions for a computer that has a name by which it can be called into action ' A traditional or established way of doing things Examples ' Installing a car battery is a simple procedure
' What is the procedure for applying for a loan'
' New employees are taught the proper safety procedures
' We must follow proper court procedure
' An identity check is standard police procedure
' The procedure for treating a burn
' The procedure will take two hours 19 | May, 2017 | Yokogawa Electric Corporation A history lesson ' Aviation standards EVERY pilot and plane whether private or commercial now uses checklists 1935 ' Dayton, OH B-17 Flying Fortress crashed
on take-off
' Too complicated
' Gust lock still engaged Test pilots developed checklists Standard global
checklists
' Pre-flight
' In flight
' Landing
' Taxiing 20 | May, 2017 | Yokogawa Electric Corporation To err is human ' Failure in maintenance procedures cost airline $150,000 fine
' Engine cover not replaced and test run not done
' Almost cost 189 lives Single largest factor in plant trips and accidents is human error ' ASM consortium analysis of 32 incident reports indicated the need to improve human reliability ' Majority of procedural operations failures due to execution failures in abnormal conditions ' Over half of the reports included recommendation to improve procedural content for abnormal conditions 42% 36% 22% 0% 10% 20% 30% 40% 50% Human error Equipment failure Process CAUSES OF ABNORMAL SITUATIONS 21 | May, 2017 | Yokogawa Electric Corporation Transient operations (i.e. start-ups/shutdowns, emergency events) ' Disproportionate percentage of incidents during transient
operations
' Conducted infrequently during start-ups, shutdowns and
abnormal events ' 10% of time is spent on transient operations yet they account for
over 50% of incidents ' Deficiencies in procedures and training cited Scott W. Ostrowski & Kelly K. Keim, ExxonMobil Chemical Company Chemical Processing Magazine, June 2010 22 | May, 2017 | Yokogawa Electric Corporation Human factors and operator errors Errors of COMMISSION: ' Performing correct step on wrong item ' Performing step incorrectly on right item ' Performing correct step at wrong time Errors of OMISSION: ' Skipping a necessary step ' Failing to communicate to a fellow worker
(spoken or written) P. L. Clemens February 2002 23 | May, 2017 | Yokogawa Electric Corporation Procedure errors & breakdowns ' 5 Refineries and Petrochem Plants
' 3 year period
' $12 million losses Thomas N. Williams, Jr. ASM Consortium Root cause category Subcategory No. % Procedure Followed Incorrectly 6 9 Format Confusing 1 Details need improvement 2 Check-off Misused 3 Procedure Wrong 28 40 Facts Wrong 3 Situation Not Covered 25 Procedure Not Followed 36 51 Procedure not used 19 No procedure 15 Procedure not available or inconvenient for use 1 Procedure difficult for use 1 24 | May, 2017 | Yokogawa Electric Corporation Procedures in process operations ' ALL process operations in ALL industries have procedural operations ' Normal, safe operation
' Change of state e.g. Start up, Shut down, Transition ' Fuel source switch, adjusting to market demands, adjust different operating
conditions and running times, meet
regulatory compliance ' Procedures may be: ' Operator Knowledge (Tribal lore)
' Manual via Written SOP's ' Semi-Automated
' Automated ' Procedures vary by industry/company/ plant, but they require consistent execution 25 | May, 2017 | Yokogawa Electric Corporation Issues in automating of procedures Redirect =7
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modifications The operational staff of the process unit often go back to using manual procedures out of frustration and inflexibly of the automated procedures 27 | May, 2017 | Yokogawa Electric Corporation Solution Introduction ' Modular Procedural
Automation (MPA)
28 | May, 2017 | Yokogawa Electric Corporation What is Modular Procedural Automation (MPA)' MPA is a solution that Captures the experience of the best operators to
preserve procedural knowledge 1 Uses a standards based approach to modularize
and automate the best practice procedures 2 Improves operational excellence and safety by
using reproducible and repeatable procedures 3 29 | May, 2017 | Yokogawa Electric Corporation Aiming to capture best operating practices OPERATOR A's PROCEDURE A B C D E F OPERATOR B's PROCEDURE A B1 C D B2 E F OPERATOR C's PROCEDURE A B C D1 D2 E F BEST-PRACTICES PROCEDURE A B1 C D1 D2 E F B2 'Having your best operators all day, every day.' Preserving Procedural Knowledge DESIRED BUSINESS OUTCOMES: Safety first: Making operations consistent no matter who you are 30 | May, 2017 | Yokogawa Electric Corporation What operation is suitable for MPA' Operation Frequency Required time Number of pages of SOP; if nothing, guess Difficulty A loss when it fails Plant start-up Once four years 48 hours 100 pages Difficult The quantity-of-production
fall by delay of start-up time Unit start-up 3 times per year 1 or 2 days 2 pages Easy The quantity-of-production
fall by delay of start-up time Change of the
quantity of
production Once a month 2 hours 1 page Difficult Off-specification, the
damage to equipment Grade change 1 time per 2 weeks 1 day 5 pages Difficult Off-specification Unit stop 3 times per year 2 hours 2 pages Easy The damage to equipment,
delay of the next starting Check of unit 2 times per year 4 hours 1 page Easy The performance fall of
equipment Operation after
safety valve
operation At the time of
generating 2 hours 2 pages Easy The damage to equipment,
delay of the next starting Check of
safety valve 2 times per year 4 hours 1 page Difficult Shutdown by miss-
operation of safety valve 31 Operation which requires a lot of manual operation on the operator stations or which requires a lot of field operation | May, 2017 | Yokogawa Electric Corporation Customer Benefit Example:
Automation of feed switch for
oil refining
32 | May, 2017 | Yokogawa Electric Corporation Manual feed switching 0 10 20 30 40 50 60 70 1 2 3 4 5 6 7 8 B roa d M o v e s Hours into Feed Switch (hr.) Time (hr.) 0 1 2 3 4 5 6 7 9 8 Reactor average temp Feed rate 33 | May, 2017 | Yokogawa Electric Corporation 0:00 1:12 2:24 3:36 4:48 6:00 7:12 8:24 9:36 After procedure automation 0 10 20 30 40 50 60 70 1 2 3 4 5 6 7 8 B roa d M o v e s Hours into Feed Switch (hr.) Manual Automated Reactor average temp Feed rate 34 | May, 2017 | Yokogawa Electric Corporation Operator uptake and proven benefits 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% J F M A M J J A S O N D USAGE Procedure Optimization 35 BENEFIT - Decreased operational variability between operating personnel
- Faster transitions
- Increased throughput
- Smoother transitions
- Increased computer monitoring of critical process variables
- Increased accuracy in executing the manufacturing planning
| May, 2017 | Yokogawa Electric Corporation Other benefit examples from our client ' Standardize and automate manual procedures ' Increase production output 200 tons per year while Reducing manufacturing time 150 hours per year ' Improve plant's operating efficiency ' Eliminated 15 sheets of check list with 264 items
' Created training tool for new operators ' Improve plant's operation safety ' Reduction in nuisance alarms
' Procedure automation prevented bypassing critical steps 36 | May, 2017 | Yokogawa Electric Corporation Success Stories 37 | May, 2017 | Yokogawa Electric Corporation 1. Acrylic acid production ' Acrylic acid production facility ' 2 reactors
' 4 distillation columns
' Crystallizer ' Regular shutdowns required for cleaning and maintenance ' Start-up procedure for Acrylic Acid manufacturing required the skills of experienced operators to bring the process up to steady state ' Additional time to bring the process to full production resulted in unnecessary rework and waste of production utilities ' Procedural automation implemented ' Process operators were able to start up their distillation columns 30% faster
' Reactors were able to come on stream 70% faster
' Process safety factors of avoiding explosive conditions during start-up were improved 38 | May, 2017 | Yokogawa Electric Corporation 1. Acrylic acid production ' Benefits Start-up time to steady state was reduced by 30% 0 1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Star t u p d u rati o n (h ) Start up process No. START UP PROCEDURE OF A COLUMN Manual Automated Average value manual Average value automated About 30% 39 | May, 2017 | Yokogawa Electric Corporation Engineering term 8 months
' Operation review
' Configuration
' Debug, operator training
' Starting operation Engineering resources Benefits 2. Automation of high-density polyethylene grade change Purpose of automation ' Higher than normal operator workload ' Product quality depending on operator ' High degree of skill required
' Frequent new products 2 people
' Skilled operator
' Process engineer Operation was fully automated
and reduced:
' Manipulations to 2 from 200
' Transition time by 10%
' Transitional products by 20%
' Engineering work load Frequency of operation Daily 40 | May, 2017 | Yokogawa Electric Corporation Engineering/ configuration term 4 months (Feb. to Jun. in 1998)
' Feb. ' March > Design ' Apr. ' May > Implementation ' June - > Actual operation Engineering resources Benefits 3. Olefin plant reactor switch Purpose of automation ' Improve production cost
' Increase productivity
' Reduce Operator workload 4 people
' Skilled operator
' Process engineer
' DCS engineer
' Consultant 1. Increased productivity ' Transition time is reduced 3 hrs ' 0.4%/year
' 134,000 USD/year 2. Reduced operator workload ' Reduced ALL DCS manipulations ' 410 hours/year-operator 3. Increased engineering efficiency ' Reduced engineering time in comparison with DCS
engineering and configuration Frequency of operation Weekly 41 | May, 2017 | Yokogawa Electric Corporation Engineering term 2 months
' Operation review
' Configuration
' Debug, operator training
' Starting operation Engineering resources Benefits 4. Automation of crude switch operation summary Purpose of automation ' Higher than normal operator workload ' Transition depending on operator
' Production loss from operator errors 2 people
' Skilled operator
' Process engineer 1. Operation was fully automated ' From 8 hours to 2.5 hours 2. Operator workload reduced ' From 130 manipulations to 10 for one crude switch
operation ' Monitoring fully automated
' 2000 process alarms were reduced during crude
switching by automatic
optimization 3. Transition time was minimized 4. Operator errors were prevented 5. Standardized operational procedure 6. Best practices were shared Frequency of operation Two to three times per week 42 | May, 2017 | Yokogawa Electric Corporation Technology & Implementation
Process
44 | May, 2017 | Yokogawa Electric Corporation Typical implementation issues ' Transitional operation is 'trial and error' operation ' Operator is not in charge of DCS configuration (process engineer is)
' Multiple field operations
' Operation know-how is not preserved VS. EXISTING DCS PROGRAM Start End Pause Pause Pause No No No Yes Yes Yes End ACTUAL OPERATION Start No Yes Yes Yes No No Recover Recover Recover Recover Know-how Know-how Know-how Yes 45 | May, 2017 | Yokogawa Electric Corporation Yokogawa's MPA solution is easy for OPERATOR Tools are designed for operators 1 ' Does NOT require control engineer ' Does NOT require DCS expertise ' Does NOT require programmer pro ' OPERATORS implement ' OPERATORS maintain DCS platform independent 2 ' One solution for all plants ' One application to learn ' One solution to maintain ' One solution that works with all automation platforms 46 | May, 2017 | Yokogawa Electric Corporation Enabling technology ' Exapilot A best practice-based operator assistance tool
that documents and automates complex
procedural operations Improving plant safety, plant stability, profitability,
and operator effectiveness Over 1320 installations worldwide (as of September 2016) 47 | May, 2017 | Yokogawa Electric Corporation Conclusion 49 | May, 2017 | Yokogawa Electric Corporation Conclusion MPA IS about improving production performance and safety Procedures conducted the same way every time Safety & environment issues Lost production opportunities PID loops in manual mode or with high operator changes MPA ADDRESSES 50 | May, 2017 | Yokogawa Electric Corporation Thank You 52


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