Post on 27-Feb-2022
Instrumented and Actuated SystemsImproving Operator Effectiveness
Mark Bitto / ABB Inc / PSPG / CIBO Technical Focus Group / June 2015
Improving operator effectivenessAbout the speaker
© ABB Inc.June 3, 2015 | Slide 2
Speaker name: Mark Bitto
Speaker title: Global Products Marketing ManagerProduct Group Automation ProductsBU Power Generation
Company name: ABB Inc.
Location: Wickliffe, OH, USA
Contact: mark.bitto@us.abb.comwww.abb.com/symphonyplus
Improving operator effectivenessIndustry trends
Generational shift in workforce
Seasoned operators retiring
Fewer, inexperienced operators entering
Consolidation of operations
Explosion of data collection
Adoption of standards
Regulation compliance
© ABB Inc.June 3, 2015 | Slide 3
Improving operator effectivenessWhy focus on the operator?
Estimated that abnormal situations account for more than $20 billion USD lost in the US economy alone
ARC estimates that almost 80 percent of these losses are preventable and 42 percent are primarily the result of operator error
Safety incidents often attributed to operator error due to poor decision making caused by the lack of information, such as procedures, and training. (www.csb.gov)
Source: ARC Advisory Group
People
42%
Process22%
Equipment36%
© ABB Inc.June 3, 2015 | Slide 4
© ABB Inc.June 3, 2015 | Slide 5
Improving operator effectivenessWhere’s the focus?
Traditional control room environments:
Complex environment with a multitude of different systems
Geographically distributed operations (remote / unmanned)
Typically no overview information to give the bigger picture
Low level of situation awareness
Poorly integrated CCTV and telecom equipment
Too many keyboards and other input devices
Non-ergonomic operator desks with built-in computers that generate heat, noise and are difficult to keep clean
Unpleasant environment, with little consideration to human factors, lighting, noise, etc.
© ABB Inc.June 3, 2015 | Slide 6
Improving operator effectiveness Where do we start?
Organizational structure, roles and responsibilities
Operator Interface Design
Alarm Management
ConditionMonitoring
Asset Utilization
Workplace design
Procedures / Workflow
Control Room Design
and Ergonomics
Operator competence, training and skills development
KnowledgeManagement Process and abnormal
situation understanding
Alertness and Fatigue
Safety Critical
Communications
© ABB Inc.June 3, 2015 | Slide 7
Improving operator effectiveness The four pillars of operator effectiveness
Maximum Operator
Effectiveness
Operator competency
Human factor ergonomics
Plant system integration
High performance
HMI
Integrated control room design
User specific workplaces
Asset management & CMMS integration
Integrated history & 3rd party systems
Plant performance optimization
Simulation solutions
Plant improvement program platform
Operator training
High performance graphics
Integrated alarm management
High performance navigations
© ABB Inc.June 3, 2015 | Slide 8
Improving operator effectivenessRemoving the isolated islands of control
Improving operator effectiveness1) Integrated process
view
© ABB Inc.June 3, 2015 | Slide 9
Improving operator effectivenessRemoving the isolated islands of control
Improving operator effectiveness1) Integrated process
view
Benefits:
• Enables centralized, consolidated operations
• Gives you one single point for vertical integration
• Seamless data presentation from varied sources, one consistent and familiar operator environment regardless of underlying control system
• Consolidated alarm and event lists simplify troubleshooting
© ABB Inc.June 3, 2015 | Slide 10
Improving operator effectivenessCentralized, consolidated and consistent operations
Improving operator effectiveness1) Integrated process
view2) Consolidated,
consistent operations environment
Alarm Group / Graphic Bars
Icon Bar Navigation
Tab / Tile Windows
GreyscaleNormal Operation
Display Select
Tag BrowserFast Search
Operator NotesPoints off scan
Operator NotesAlarm and Event List
Operating ParametersRed Tag
Side MenuFlyout Navigation
© ABB Inc.June 3, 2015 | Slide 11
Improving operator effectivenessContextual navigation
Improving operator effectiveness1) Integrated process
view2) Consolidated,
consistent operations environment
3) Contextual access
© ABB Inc.June 3, 2015 | Slide 12
Improving operator effectivenessUser specific workplaces
Improving operator effectiveness1) Integrated process
view2) Consolidated,
consistent operations environment
3) Contextual access
EngineeringManagement
OperationsMaintenance
© ABB Inc.June 3, 2015 | Slide 13
Improving operator effectivenessInform with context to drive effective actions
Operator interface design should promote the most efficient way to detect and correct abnormal situations
High Performance is more than just grey-scale displays
It is a state of the art methodology that promotes abnormal situation awareness and operator response
Improving operator effectiveness1) Integrated process
view2) Consolidated,
consistent operations environment
3) Contextual access4) High performance
graphics
© ABB Inc.June 3, 2015 | Slide 14
Improving operator effectivenessInform with context to drive effective actions
Examples of abnormal situational awareness display hierarchy
• Overview Surveillance (top right)
• Process Surveillance (right)
• System, Sub-system Detail (below)
• Diagnostic Detail (below left)
Improving operator effectiveness1) Integrated process
view2) Consolidated,
consistent operations environment
3) Contextual access4) High performance
graphics
© ABB Inc.June 3, 2015 | Slide 15
Improving operator effectivenessAdvanced alarm handling and analysis
Improving operator effectiveness1) Integrated process
view2) Consolidated,
consistent operations environment
3) Contextual access4) High performance
graphics5) Integrated alarm
management
Source: Matrikon
Poor alarm management leads to operator ambivalence
Operators totally ignore the alarm horn and "run on instinct"
Operators have cut the wires to the alarm horn because it “went off too often”
High rates of “false” alarms influence the perception of “real” alarms
Overload of operator short term memory
EEMUA O&G PetroChem Power Other
Average alarms per day 144 1200 1500 2000 900
Average standing alarms 9 50 100 65 35
Peak alarms per 10 minutes 10 220 180 350 180
Average alarms / 10 minute interval 1 6 9 8 5
Distribution % (Low / Med / High) 80 / 15 /5 25 / 40 / 35 25 / 40 / 35 25 / 40 / 35 25 / 40 / 35
© ABB Inc.June 3, 2015 | Slide 16
Improving operator effectivenessAdvanced alarm handling and analysis
Improving operator effectiveness1) Integrated process
view2) Consolidated,
consistent operations environment
3) Contextual access4) High performance
graphics5) Integrated alarm
management
ISA 18.2 / EEMUA 191 alarm management life cycle
Next Generation HMI ISA 18.2 / EEMUA 191-compliant alarm analysis tools help users categorize occurring alarms, while the integrated alarm management system keeps operators focused.
User defined filters
Alarm and event frequency
Priority distribution
Alarm performance levels
HMI integrated alarm analysis tools
© ABB Inc.June 3, 2015 | Slide 17
Improving operator effectivenessAdvanced alarm handling and analysis
Improving operator effectiveness1) Integrated process
view2) Consolidated,
consistent operations environment
3) Contextual access4) High performance
graphics5) Integrated alarm
management
Next Generation HMI ISA 18.2 / EEMUA 191-compliant alarm analysis tools help users categorize occurring alarms, while the integrated alarm management system keeps operators focused.
x
User defined filters
Alarm and event frequency
Priority distribution
Alarm performance levels
Advanced alarm analysis tools Instantaneous reports Alarm / Event frequency Alarms over time Priority distribution Alarm duration Time to acknowledge Alarm performance Loops in manual Operator actions Exceeding threshold Standing alarms Co-occurences
Alarm presentation features Alarm grouping Alarm filtering Alarm inhibiting Alarm shelving Alarm suppressing
© ABB Inc.June 3, 2015 | Slide 18
Improving operator effectivenessAsset management and optimization
Improving operator effectiveness1) Integrated process
view2) Consolidated,
consistent operations environment
3) Contextual access4) High performance
graphics5) Integrated alarm
management6) Integrated asset
management
Wealth of plant data used to identify and alert on degrading asset performance before failure occurs
All asset levels: field devices, process / electrical / environmental equipment, control loops, power supplies, communication and network equipment, etc.
Moves maintenance from corrective maintenance program to proactive or predictive maintenance program
© ABB Inc.June 3, 2015 | Slide 19
Improving operator effectivenessIntegrated operations and maintenance
Improving operator effectiveness1) Integrated process
view2) Consolidated,
consistent operations environment
3) Contextual access4) High performance
graphics5) Integrated alarm
management6) Integrated asset
management7) Streamlined work
processesPlant – normal state
High Performance HMI alarm notification
SMS alarm notification+
Call acknowledgement
Proactive response Engineering
Operations
Management
Plant – alarm state
Maintenance
SMS notification:
• Allows for easy alarm notification with remote users
• Quick resolution of maintenance issues before failure
© ABB Inc.June 3, 2015 | Slide 20
Improving operator effectivenessIntegrated operations and maintenance
Improving operator effectiveness1) Integrated process
view2) Consolidated,
consistent operations environment
3) Contextual access4) High performance
graphics5) Integrated alarm
management6) Integrated asset
management7) Streamlined work
processes
Plant – normal state
High Performance HMI alarm notification
Proactive response
Plant – alarm state
Seamless interaction between plant HMI and CMMS
View current CMMS schedules directly from HMI
If not scheduled, create and submit CMMS work order report from HMI
CMMS integration:
Allows for easy communication with and navigation to asset-specific maintenance activities
Quick resolution of maintenance issues before failure
© ABB Inc.June 3, 2015 | Slide 21
Improving operator effectivenessEmbedded security features
Improving operator effectiveness1) Integrated process
view2) Consolidated,
consistent operations environment
3) Contextual access4) High performance
graphics5) Integrated alarm
management6) Integrated asset
management7) Streamlined work
processes8) Inherent security
Built in cyber security for software, systems and devices User Authentication Role Based Access Control Event Logging / Audit Trails Backup / Restore Hardened Hosts Host Firewall Configuration Antivirus Network Zones Etc.
© ABB Inc.June 3, 2015 | Slide 22
Improving operator effectivenessOperator competency
Improving operator effectiveness1) Integrated process
view2) Consolidated,
consistent operations environment
3) Contextual access4) High performance
graphics5) Integrated alarm
management6) Integrated asset
management7) Streamlined work
processes8) Inherent security9) Operator training
simulators
Operator training simulation provides training of personnel to familiarize operator with their actual work environment
Includes trainer station to set initial conditions, review performance / playback, tied to models of plant equipment
Additional benefits include reduce time to commission and provides testing environment
© ABB Inc.June 3, 2015 | Slide 23
Improving operator effectivenessAttention to human factors
Improving operator effectiveness1) Integrated process
view2) Consolidated,
consistent operations environment
3) Contextual access4) High performance
graphics5) Integrated alarm
management6) Integrated asset
management7) Streamlined work
processes8) Inherent security9) Operator training
simulators10) Integrated control
room design
Human factors and ergonomics is concerned with the "fit" between the user, equipment and their environments.
Reducing stress and fatigue
Increases performance and alertness
Reduced health issues and turnovers
Operator environment can help retain
existing resources and attract new
talent
© ABB Inc.June 3, 2015 | Slide 24
Improving operator effectivenessErgonomic control room design
Improving operator effectiveness1) Integrated process
view2) Consolidated,
consistent operations environment
3) Contextual access4) High performance
graphics5) Integrated alarm
management6) Integrated asset
management7) Streamlined work
processes8) Inherent security9) Operator training
simulators10) Integrated control
room design
Personalized ergonomics
Collaboration platform
Cockpit solution
Comply with today’s and future Human Factor requirements
© ABB Inc.June 3, 2015 | Slide 25
Improving operator effectiveness Summary
Improving the operator’s visibility to plant performance while filtering out the “noise” will lead operators to greater
awareness, faster response, and better decisions
© ABB Inc.June 3, 2015 | Slide 26
Improving operator effectivenessSummary: Case examples
Improving operator effectiveness1) Integrated process
view2) Consolidated,
consistent operations environment
3) Contextual access4) High performance
graphics5) Integrated alarm
management6) Integrated asset
management7) Streamlined work
processes8) Inherent security9) Operator training
simulators10) Integrated control
room design
Source: the High Performance HMI Handbook by Bill Hollifield, Dana Oliverr, Ian Nimmo, and Eddie Habibi : quoting studies done by ASM – Abnormal Situation Management
TaskWith
traditional HMI
With high
performance HMIResult
Detecting abnormal situations before alarms occur
10% of the time 48% of the time 5x increase
Success rate in handling abnormal situations
70% 96% 26% over base
case
Time to complete abnormal situation tasks 18.1 min 10.6 min 41% reduction
© ABB Inc.June 3, 2015 | Slide 27
Improving operator effectivenessSummary: For your consideration
Improving operator effectiveness1) Integrated process
view2) Consolidated,
consistent operations environment
3) Contextual access4) High performance
graphics5) Integrated alarm
management6) Integrated asset
management7) Streamlined work
processes8) Inherent security9) Operator training
simulators10) Integrated control
room design
Large financial impact for small improvements in: Availability, Performance, Quality
US Paper AverageTotal Time
8,760 8,760 Theoretical Prod/Year Actual Prod/Year
179,907 145,581 179,907 150,320
Production Rate (T/Hr)
Contribution
Margin/Year
20.54 OEE 45,857,487 20.54 80.9% 47,350,456 Profit
83.6% 9,384,033 Contribution Margin/Unit 10,805,573
Availability 315.0089.8% 315.0090.8%
Direct Maintenance Fixed Costs/year Revenues Profitability Delta (Annual)
Performance Price/Unit Pct Change 9,193,125 36,473,454 101,906,406 9.21% 1.06%93.0% $700.00 0 9,193,125 36,544,883 105,224,142 10.27% 1,421,540$ 94.0% $700.00
Depretiation Fixed Assets Profit ROCE
Quality Yield Variable Cost/Unit 4,000,000 200,000,000 9,384,033 4.56% 0.69%97.0% $385.00 4,071,429 200,000,000 10,805,573 5.25%98.0% $385.00
Labor & Other fixed costs NOWC Capital Employed
Pct Change 23,280,330 6,000,000 206,000,000 0 23,280,330 6,000,000 206,000,000
7,089
0%10%20%30%40%50%60%70%80%90%
100%
1
Baseline
Quality
Performance
Availability
NetProduction 7,319
0%
20%
40%
60%
80%
100%
1
WITH IMPROVEMENTS
Quality
Performance
Availability
Net Production
ROCE
Profitability
OEEMaintenance Cost
Revenues
4.20%
4.40%
4.60%
4.80%
5.00%
5.20%
5.40%
1 2
Financial Impact:
Profitability &
Return on Capital
Employed (ROCE)Availability
Performance
Quality ROA = Income / Assets
© ABB Inc.June 3, 2015 | Slide 28
Improving operator effectivenessSummary: For your consideration
Improving operator effectiveness1) Integrated process
view2) Consolidated,
consistent operations environment
3) Contextual access4) High performance
graphics5) Integrated alarm
management6) Integrated asset
management7) Streamlined work
processes8) Inherent security9) Operator training
simulators10) Integrated control
room design
Large financial impact for small improvements in: Availability, Performance, Quality
US Paper AverageTotal Time
8,760 8,760 Theoretical Prod/Year Actual Prod/Year
179,907 145,581 179,907 150,320
Production Rate (T/Hr)
Contribution
Margin/Year
20.54 OEE 45,857,487 20.54 80.9% 47,350,456 Profit
83.6% 9,384,033 Contribution Margin/Unit 10,805,573
Availability 315.0089.8% 315.0090.8%
Direct Maintenance Fixed Costs/year Revenues Profitability Delta (Annual)
Performance Price/Unit Pct Change 9,193,125 36,473,454 101,906,406 9.21% 1.06%93.0% $700.00 0 9,193,125 36,544,883 105,224,142 10.27% 1,421,540$ 94.0% $700.00
Depretiation Fixed Assets Profit ROCE
Quality Yield Variable Cost/Unit 4,000,000 200,000,000 9,384,033 4.56% 0.69%97.0% $385.00 4,071,429 200,000,000 10,805,573 5.25%98.0% $385.00
Labor & Other fixed costs NOWC Capital Employed
Pct Change 23,280,330 6,000,000 206,000,000 0 23,280,330 6,000,000 206,000,000
7,089
0%10%20%30%40%50%60%70%80%90%
100%
1
Baseline
Quality
Performance
Availability
NetProduction 7,319
0%
20%
40%
60%
80%
100%
1
WITH IMPROVEMENTS
Quality
Performance
Availability
Net Production
ROCE
Profitability
OEEMaintenance Cost
Revenues
4.20%
4.40%
4.60%
4.80%
5.00%
5.20%
5.40%
1 2
Financial Impact:
Profitability &
Return on Capital
Employed (ROCE)Availability
Performance
Quality ROA = Income / Assets
Q: What is the impact of improving Operator Effectiveness at your facility?
A: Small improvements in Availability, Performance, and Quality can result in large bottom-line financial impact
Availability improvements: How many spurious trips, process upsets, and unplanned outages can be avoided with better
situational awareness, improved navigation, better control visibility, effective alarm management, and better contextual information?
Performance improvements: How much time can be saved with improved navigation, better asset performance visibility, effective
alarm management, better contextual information, and streamlined work processes?
Quality improvements: How many environmental events, regulatory fines, safety events can be avoided with better situational
awareness, improved navigation, better control visibility, better asset performance visibility, effective alarm management, and better contextual information?