AutomatingProceduresin

Continuous Process
ContinuousProcess
ApplicationsusingISA106
DaveEmerson
Director,
U.S.DevelopmentCenter
Yokogawa

LeilaMyers
ConsultingEngineer
USMK
Yokogawa

MESAKNOWS

SUSTAINABILITY&ECOEFFICIENCY LEAN METRICS&PERFORMANCEMANAGEMENT

INFORMATIONINTEGRATION SAFETY ASSETPERFORMANCEMANAGEMENT B2MML
QUALITY&COMPLIANCE PRODUCTLIFECYCLEMANAGEMENT AUTOMATION

Doyouknow MESA?

TodaysGoals
Provideanoverviewofcurrentstandardization
activitiesregardingautomatedprocedures
Explainhowyoucangetstarted

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Agenda
AutomatedProceduresIntroduction DaveEmerson

HistoricalPerspective
Historical
Perspective
ISA106StandardsCommittee
BenefitProposition
E
Examples
l
ISA106TechnicalReportConcepts

ModularProceduralAutomation(MPA) LeilaMyers

WhatisMPA?
ConsultingMethodology
g
gy
Howtoselecttherighttoolforthejob
Exapilotexamples
CENTUM VP examples
CENTUMVPexamples

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HistoricalPerspective(1of3)
Overthecourseofthecontinuousprocessindustryslife
there has been steady movement to automate
therehasbeensteadymovementtoautomate
procedures
Intheearlydaysoperationwasmanual
h
l d
l
Alloperationsdoneinthefield
Lotsofpeoplerequired,fewvalvesperperson
Proceduresused,maynotofbeenwritten

1st automationwasprobablybringingmeasurementsto
automation was probably bringing measurements to
theoperator
Lessfieldworkrequired,oratleastlessclimbing!
Quickerfeedbacktooperatorsonactionstheyperformed
Quicker feedback to operators on actions they performed
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HistoricalPerspective(2of3)
Remoteactuatorsonvalvesintroduced
Operatorscouldmanagelargerpartsoftheprocess
Fewerfieldoperators

PIDcontrollersremovedoperatorsfromtheloop
p
p
Operatorsnowsupervisedloops,nolongerperformed
control
Operatorscouldmanagerlargerpartsoftheprocess

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HistoricalPerspective(3of3)
ComputerbasedcontrolsystemsDistributedControl
Systems Centralized control rooms Advanced Process
SystemsCentralizedcontrolroomsAdvancedProcess
Control
morepiecesofprocessequipmentaremergedintolargerand
more complex control strategies
morecomplexcontrolstrategies
Additionallayersofabstractiontakesplace

B
But,inmostcontinuousprocessplantsoperatorsstill
t i
t
ti
l t
t
till
performmostproceduresmanually
Complexprocedures
Startingadistillationcolumn

Repetitiveprocedurestheoperatoraddslittlevalueto
Startingpumpsetsbycontrollingindividualvaluesandpump
controls
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WhyNotJustUseISA88?
Inthe17yearssinceISA88hasbeenastandardithasbeen
widely adopted in the batch industry, but only used on an
widelyadoptedinthebatchindustry,butonlyusedonan
individualbasisinthecontinuousprocessindustries
Whenusedforcontinuousprocessestweakshadtobemade,sonot
aperfectfit

Continuousprocesseshavedifferentcharacteristicsfrombatch
Ingredientsnottreatedthesame
Manydifferentproceduresused,notalwaystiedinanicerecipe
bundle
Equipmentindependencenotasignificantfactor
Nosignificantadoption,Timeforsomethingdifferent
ISA106isanattempttogetthecontinuousprocessindustriesto
ISA106 is an attempt to get the continuous process industries to
discussandstandardizeprocedureautomationholistically
Goal:Makeprocedureautomationanexpectedpartofanycapital
project

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ISA106
ISAstandardscommittee
Creatingastandard
ProcedureAutomationforContinuousProcess
O
Operations
ti

Membership
Owner/Operators
Owner/Operators,
Suppliers,
Consultants
Opentoany
interestedpersonor
company
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ThepowerofknowingwhatMESAKNOWS

Membership(partial)

ABB
Aramco Services Co
AramcoServicesCo
AREVA
BayerMaterialScience
BPLubricants
Braskem
CDMSmith
CH2MHILL
Chevron
Conocophillips
DSMCorporateOperations
DuPont
EmersonProcessManagement
ExxonMobil
Herman Storey Consulting
HermanStorey

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Honeywell
Innovatia
Invensys
MustangAutomationandControl
NovaTech ProcessSolutions
PAS
Prosys
RockwellAutomation
RSISimcon
SaudiAramco
SavannahRiverNuclearSolutions
Shell
Shell
TheDowChemicalCompany
ValeroEnergyCorp
Yokogawa

ThepowerofknowingwhatMESAKNOWS

CommitteeWorkItems
RecentlycompletedthefirstofthreeTechnical
Reports
TR#1 ProcedureAutomationforContinuousProcess
Operations
Modelsand
Terminology
TR#2
TR #2 Examples
TR#3 AutomatedProcedureLifecycle

Standard
Standardwillbeproducedbaseduponthe
ill be prod ced based pon the
TechnicalReportsandindustryfeedback

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BenefitProposition
Automatingprocedures
Improvesbusinessresults
Reducesrisk feweroperationalerrors
Ensurescompliance

Studieshaveshownthatprocedureerrorsarea
primarycauseofmanyincidents

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ProceduralOperations
ALLprocessoperationsinALLindustrieshave
proceduraloperations
Normal,safeoperation
Changeofstatee.g.Startup,Shutdown,Transition

Proceduresmaybe:

OperatorKnowledge(Triballore)
ManualviaWrittenSOPs
SemiAutomated
Automated

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RefineryIncidents FAT/CATs
KernOilRefineryinBakersfield,CaliforniaonJanuary19,2005
IIncidentkilledoneemployeeandcausedmultipleinjuriestoother
id
kill d
l
d
d
li l i j i
h
employees
Crudeunitstartup
Workersoverpressurizedapumpcasingwhichcatastrophically
ruptured,releasingandignitinghotoilthatimmediatelyexploded

GiantIndustriesCiniza Refinery,Gallup,NewMexico,April8,
2004
6employeeswereinjured,4requiringhospitalizationwithserious
burninjuries
Duringhydrofluoricacid(HF)alkylationunitmaintenanceashutoff
valvewasnotclosedasrequired,causedreleaseofflammableliquids
andvaporswhichcausedsubsequentexplosions

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TypicalTargetsforAutomated
Procedure
Refining
TransitionManagement
Transition Management CrudeSwitchover
Crude Switchover
Regeneration

Petrochemical

Startup/Shutdown
TransitionManagement GradeChanges
LineSwitchover
Cleaning

Polymers
Gradechange
g
Switchover

Furnaces
Decoking
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Refinery TransitionAutomation
Opportunitytoautomateafeedswitch
Benefits:

Operatorworkloadreducedby60%
A42%reductioninproductyieldloss
I
Increasedfeedthroughputduringtransitionby18%
d f d th
h td i t
iti b 18%
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-up
p time

Reactors able to
come on stream
70% faster

Process safety
margins, of
explosive conditions
during startup,
were significantly
increased

Start up procedure of a column

5
manual
automated

Start up duration [h]

4
Average value manual

about 30 %

3
Average value automated

Start up process No.

10

11

12

13

14

15

16

17

NPRA2011:AM1167NewDevelopmentsandBestPracticesinAutomatingProceduralOperationsforContinuous
Processes
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BenefitsDerivedfrom
Automating Procedures
AutomatingProcedures
Improvedsafety
performance
f
Improvedreliability
Moreconsistentoperation
p

Reducedlosses
Feweroperatorerrors
Improvedresponsesto
disturbances

IncreasedProduction
Faster&moreconsistent
startupsandshutdowns
Moreefficienttransitions

Copyright2012,MESAInternational

ImprovedOperator
Eff i
Effectiveness
Automatedprocedures
are tools for the
aretoolsforthe
operator
Knowledgecapture
Improvedtraining

Improvedinsightintothe
process
p
Designprocesscan
improveprocedures

ThepowerofknowingwhatMESAKNOWS

ModelsandTerminology
1stTechnicalReport
Statescommitteescurrentthinkingonhowto
organizeandapproachprocedureautomation

Models
Conceptstogivetheindustryacommonmental
modelforautomatedprocedures

Terminology
Definitionstogivetheindustryacommonlanguage
forautomatedprocedures

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PhysicalModel
Enterprise

Enterprise
Site

Enterprise
Plant

Enterprise
Plant Area

Enterprise
Unit

Enterprise
Equipment

Enterprise
Device

Copyright2012,MESAInternational

Organizesphysicalequipmentintoa
hierarchy
Providesacommonsetoftermsand
equipment levels for companies &
equipmentlevelsforcompanies&
industriestomaptheirtermsto
Commontermsenableproductsandpeopleto
p
p p
workmoreefficientlywithdifferent
owner/operators.

Physicalmodelisthefoundationofthe
h
l
d l h f
d
f h
ISA106work
Each
Eachiteminthemodelcanhave
item in the model can have
procedures
ThepowerofknowingwhatMESAKNOWS

PhysicalModel Today
Enterprise

Enterprise
Site

Results of committee owner/operator terminology

Enterprise
Plant

Enterprise
Plant Area

Enterprise
Unit

Enterprise
Equipment

ISA106

Chemical
Company

Enterprise

Enterprise

Site

Site

Site

Plant

Plant

Complex

PlantArea

Area

Plant

Unit

Unit

Unit

Equipment

Equipment

Device

Device

OilRefinery

OffshoreOil OffshoreOil
Platform
Platform
Example1
Example2

Paper
Industry

Field
Platform

Platform
Package

Enterprise
Device

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Device

ThepowerofknowingwhatMESAKNOWS

Mill

PhysicalModel Examples
Enterprise

Enterprise
Site

Results of committee owner/operator terminology

Enterprise

Corporate

Division

Business
Unit

Site

Complex

Train

Facility

Plant

Platform

Train

Enterprise
Plant

Enterprise
Plant Area

Enterprise
Unit

Subsea

Verbund

Gas
Compression Dehydration

Separation

Train

Injection

Utilities

Water
Treating

Unit

p
Separator

Dry/WetOil
T k
Tanks

Pipeline
P
Pumps

Equipment

PumpSet

Feed System

Reboiler

Sampling
System

Device

Control
Valve

Transmitter

Pump

Analyzer

PlantArea

Enterprise
Equipment

Enterprise
Device

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Field

Production
Manifold

Wells

Hydrocyclone
y
y
Compressor
p
Compressor

ThepowerofknowingwhatMESAKNOWS

EthyleneFurnaceExample
PlantArea

Unit
Furnace 1

Furnace 3

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Furnace 2

Furnace 4

Furnace 5

ThepowerofknowingwhatMESAKNOWS

EthyleneFurnaceExample
PlantArea
Discharge

Unit

QUENCHTOWER

29
DECOKEDRUM

Equipment
Air & Fuel Input
Heater

Device

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ProcedureRequirementsModel
Enterprise
Procedure
Requirements
Site
Enterprise
Procedure
Requirements
Plant
Enterprise
Procedure
R
Requirements
i
t
Plant Area
Enterprise
Procedure
Requirements
Unit
Enterprise
Procedure
Requirements
Equipment
Enterprise
E
t
i
Procedure
Requirements

Proceduresareassociatedwithobjectsin
the physical model
thephysicalmodel
Mostcommonforunits,equipmentand
devices

Definitionoftheprocedure
Whatmustbedonetoaccomplishits
p
objective
Functionalrequirementfortheautomated
procedure
d

Device
Enterprise
Procedure
Requirements

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ProcedureImplementationModel
Site Implementation
Modules

Plant
Implementation
Modules
Plant Area
Implementation
Modules
Unit
Implementation
Modules
Equipment
Implementation
Modules

Theactualautomatedprocedure
P
Program,functionblock,sequentialfunction
f ti bl k
ti l f ti
chart,flowchart,

Thedesignofimplementationmodulesisan
The
design of implementation modules is an
engineeringprocess
Procedurerequirementsarethespecification
q
p
Notalwaysa1:1mappingwithprocedure
requirements

Control
Implementation
Modules

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ImplementationModules
Site Implementation
Modules

Plant
Implementation
Modules
Plant Area
Implementation
Modules
Unit
Implementation
Modules
Equipment
Implementation
Modules

Consistofasetoforderedtasks
Tasksmaycontaintasks
T k
t i t k

Tasksperformstepbystepactions
Commands

Notifications

Tasks
Programming
Continuous
Control

Human
Interface

Commands
and
Notifications

Human Actions
Control
Implementation
Modules

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Commands

Peer to
Peer

Notifications

ThepowerofknowingwhatMESAKNOWS

ImplementationModules
Implementationmethodsareanytypeoftoolusedtocreatea
task.
k
Programming
ContinuousControl
HumanActions.

Commands

Examplesofprogrammingtypes

Computerprograms
C
t
Configurablefunctionblocks
Continuouscontrolfunctions
Executableflowcharts.
ProcedureFunctionCharts(PFC)
Sequential Function Charts (SFC)
SequentialFunctionCharts(SFC)

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Notifications

Tasks
Programming
Continuous
Control

Human
Interface

Commands
and
Notifications

Human Actions

Commands

Peer
ee to
o
Peer

Notifications

ThepowerofknowingwhatMESAKNOWS

ProcedureExecution

Procedure
Implementation Module
Task

EachProcedure,Implementation
Module & Task has 3 execution work
Module&Taskhas3executionwork
items
Command Trigger

Task . . . Task

Perform Actions
Actions
Verify Success/Failure

Implementation Module
Task Task

Command
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Task

Task

Computer/HumanMix
CPVworkitemscanbedoneby
acomputerorhuman

Perform

Verify

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ImplementationModuleExecution
Threeworkitemsaretypicallyusedfor
implementationmoduleexecution:
Command Thetriggertoinitiatetheimplementation
module.Whenreceivedthiscausesthe
implementationmoduletoperformitstasks.
Perform
Perform Theexecutionofanimplementation
The execution of an implementation
modulestasks.
Verify
Verify Verificationthattheimplementationmodule
Verification that the implementation moduless
taskswereperformedsuccessfullyorfailed.

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AutomationStyles
Organizationofthestructureofthe
implementationmodulesuchasusingprocedure
sectionsorprocessstates
Useofcomputeroroperatoractionfor
command,perform,verify
Amountofprecisionusedforverification
Humanmachineinterfacephilosophy
p
p y
Degreeofautomationfromminimalautomation
tocomplexautomation
to
co p e auto at o
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AutomationStyleExamples
Manual
TheOperatorisresponsibleforthecommand,
performandverifyworkitems,minimalautomationis
used

ComputerAssisted
Operatorandcomputershareresponsibilityforthe
p
p
p
y
command,performandverifyworkitems.The
amountofautomationusedmayvary.

FullyAutomated
F ll A t
t d
Computerisresponsibleforthebulkofthecommand,
perform and verify work items
performandverifyworkitems.
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OperatorNotifications
Operator
Notification Types
NotificationTypes

Operatorisexpected
Operator
is expected
totakeanaction

Operatormightneedtobe
awarebutisnotrequiredto
takeaction

Arisesfromanabnormal
processorequipment
situation(ISA18.2)

Alarm

Alert

Arisesfromanormal
situation ((ISA106))

Prompt

StatusNotification

ISA106hasworkedwithISA18.2
whichhaspublishedanalarmmanagementstandard
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StatebasedControl
Aplantautomationcontroldesigntechniquethat
assignsprocessstatesanddefinedtransition
procedures
Mosteffectiveattheunitlevel
Providesahighdegreeofautomation
Startup,Shutdown,Transitions,AbnormalSituation
Responses

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Not Ready
(Out of Service)

Not Ready
Mode of Operation

Preparing

Preparing
Mode of Operation

Ready
(Idle)

Ready
Mode of Operation

State-based
Control Example
Prepare Procedure

Procedure
Implementation Module
Task

Task

. . . Task

Filling
g
Startup
Mode of Operation

Running

Task

Running
Mode of Operation

Production Rate of Change

Procedure
Abnormal Condition Handling
Procedure

Shutting Down
Mode of Operation

Controlled Shutdown Procedure

Abnormal
(Off Spec)

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Implementation Module
Task Task

Heating

Shutting Down

Startup Procedure

ThepowerofknowingwhatMESAKNOWS

Task

ControlSystemArchitecture
ManualProcedures

Operator

BasicProcess
ControlSystem

AdvisoryComputer
Procedure
Implementation
Modules

Inputs

HumanMachine
e a e
Interface

Controller
C
t ll
Procedure
Implementation
Modules

Outputs

SafetyInstrumented
System
Auxiliarycontrolsystem
(PLC,compressorcontrol,skid,
robot,vision,)
b
)

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ISA106KeyModels
Physical Model

Procedure
Requirements Model

Enterprise

Enterprise
p
Procedure
Requirements

Procedure
Implementation Model

Enterprise
Site

Site
Enterprise
Procedure
Requirements

Site
Implementation
Modules

Enterprise
Plant

Plant
Enterprise
Procedure
Requirements

Plant
Implementation
Modules

Enterprise
E
t
i
Plant Area

Plant
Enterprise
E
t Area
i
Procedure
Requirements

Plant Area
Implementation
Modules

Enterprise
Unit

Unit
Enterprise
Procedure
Requirements

Unit
Implementation
Modules

Enterprise
Equipment

Equipment
Enterprise
Procedure
Requirements

Equipment
Implementation
Modules

Enterprise
Device

Device
Enterprise
Procedure
Requirements

Control
Implementation
Modules

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Part1Summary
Automatedproceduresincontinuousprocess
operationscanhelpmakeaplantsafer&more
competitive
Automatedproceduresarenotwidelyusedtoday
Greatopportunityforimprovement

ISA106isopentoallinterestedparties
ISAmembershipisnotrequired

TR#1isthefirststep
Weneedmoreindustryinput
y p
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Copyright2012,MESAInternational

ThepowerofknowingwhatMESAKNOWS