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Transcript of eBook: Modular Procedural Automation (MPA) - preview
How to Enhance
Production and Safety
for Process Industries
Contents
2
1. Industry Challenges 3
1.1 Constrained Worker Resources 5
1.2 Operational Safety 7
1.3 Operational Consistency 10
2. An Introduction to MPA 12
3. MPA to the Rescue 15
4. Identifying MPA Opportunities 22
5. Implementing MPA 24
6. Summary & Next Steps 25
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Modular Procedural Automation eBook 3
Industry Challenges
Process industries face numerous challenges – keeping health, safety, and
environment (HSE) at the forefront, an aging workforce, improving equipment
availability, maintaining quality, and increases in operator workloads. Distracted
operators make mistakes, especially during transitions, and operational error is the
single biggest reason for unscheduled shutdowns. In this chapter we will take a
closer look at some of these challenges and how procedures play an important
role. First let’s clarify what a procedure actually is.
Chapter 1
It seems that procedures may not be the first thing that comes to mind when thinking about process
automation. Still, they play an important role at any industrial plant or factory, and though we like to refer to
the process industries as being largely “continuous,” most continuous processes actually have multiple
‘operating states.’ Process manufacturing is constantly in flux, and because of this, procedures exist. In
fact, the entire world of process operations is governed by procedures.
Fig. Typical depiction of continuous process with procedures for each operating state or phase.
What is a Procedure?
Procedures are best described as pre-set
tasks that are consistently completed in a
specific order so as to achieve the desired
result. The automation of these
procedures bridges the gap between the
process control systems and plant
operators by augmenting operator actions
with electronic Standard Operating
Procedures (SOPs) that are integrated
with a Distributed Control System (DCS).
Whether you are initiating a startup,
shutdown, grade change, or are in the
middle of a maintenance turnaround, your
plant is governed by procedures and
transitional states that can either run
smoothly and provide you with superior
plant performance, a safe and orderly
start-up/shutdown, or, they can cost you in
terms of unplanned shutdowns, incidents,
lost production, and lost opportunities.
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Modular Procedural Automation eBook 4
Manual, prompted and automated procedures, and the problem
of ‘Spaghetti Code’
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1.1 Constrained Worker Resources Skilled workers are retiring. Before
addressing a solution to the problem of
‘spaghetti code,’ we will address three
major challenges many industrial
companies are facing, starting with an
aging workforce. According to an Ernst
& Young study, one of the common
challenges all verticals within the oil
and gas sector currently face is,
planning for the sustained availability of
a competent workforce over the next
five years. A serious challenge,
especially since we know that many
plants and factories are relying on
experienced operators for dealing with
the procedures. Could your journey to
operational excellence be threatened
by an aging workforce that is retiring?
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Modular Procedural Automation eBook 6
1.2 Operational Safety Operational Safety. Besides challenges
related to workforce issues, another
primary challenge for industrial industries
is (operational) safety. Environment and
safety issues are major topics on a global
scale. In addition, there are increased
risks of accidents, and the need to
ensure safety and environmental
stewardship to actively prevent industrial
accidents from occurring is significant. If
accidents do occur, the expectation is to
prevent their impact from spreading
externally. Unfortunately, there are
several recent examples to show that
safety remains a constant challenge and
must become the highest priority for any
company or industry.
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Modular Procedural Automation eBook 7
1.3 Operational Consistency Do all of your shifts perform at high
levels? What is your strategy for
handling abnormal conditions?
How do you manage Transitions, Start
Ups, and Shut Downs? Research has
shown that the largest reason for
unscheduled downtime is operational or
human error, which accounts for
approximately 42 percent of the
unscheduled shutdowns in the process
industries. Of that 42 percent, 16 percent is
directly related to procedural error. One of
the major concerns in plant operations is
how to reduce its operation costs so that
the profit is optimized. The industrial plant
operations are fully automated with
process control systems; however, startup,
shutdown, load/grade changes, and other
non-routine works are largely done by
manual operations. So, how do you
maintain consistent operation and achieve
maximum operational throughput?
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Modular Procedural Automation eBook 8
MPA Introduction
To deal with some of the challenges described in the pervious chapter, consider
Modular Procedural Automation (MPA). It is a solution that captures operators’
knowledge and best practices and ensures procedures are consistently employed
throughout the manufacturing process. Using the capabilities of MPA, plant
operations, engineering, HSE and management can be more confident that the
correct procedures are being followed. MPA is a clear path to operational
excellence in the process industries.
Chapter 2
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Modular Procedural Automation
ISA 106 Standard - ISA 106 Standards
Committee creates a standard for
procedure automation for continuous
process operations. It’s purpose is to
develop standards, recommended
practices, and technical reports on the
design and implementation of
procedures for automating continuous
process operations – See more at:
www.isa.org
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Modular Procedural Automation eBook 10
Procedural Automation to the
Rescue
Modular Procedural Automation offers several advantages to plant operations and
contributes to achieving operational excellence. Operational excellence isn’t
necessarily an endpoint for an organization; rather, it is an ongoing journey. It
focuses on minimizing and managing downside risks while maximizing an
operation’s performance and shareholder value. Along the journey, multiple
factors play a role. In this chapter we will outline the main benefits of MPA.
Chapter 3
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Modular Procedural Automation eBook 11
Capturing Knowledge MPA is like having your best
operators all day, every day. Many
procedures are not well documented.
Most plants therefore depend on the
knowledge of those few skilled
operators who know how procedures
are to be performed, sometimes in
accordance with documented
instructions (assuming they exist), and
sometimes following the "right way" in
spite of what the instructions say. As a
result different operators may practice
them differently. Part of automating
such procedures is determining the
best practices and incorporating those
approaches, so they will be followed
consistently.
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Modular Procedural Automation eBook 12
Enhancing Safety with MPA With MPA, Operators Are Never
Alone. Regardless of the reasons, the
control rooms of the western world do
not seem to be as well-manned as
those of 20 or 40 years ago. To
address this situation, MPA can be
used to transfer the knowledge and
experience of the best remaining
operators, engineers and technicians to
new operators. This makes new
operators more effective and efficient.
When MPA is correctly implemented,
no operator needs to start, run or stop
an operating unit alone.
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Modular Procedural Automation eBook 13
Operational Consistency & MPA
Transitions inherently increase the risk
of disruptions that can lead to incidents
and production downtime. Research
indicates that nearly 80% of production
downtime is preventable. And half of
them is due to operator error. The
monetary costs of this failure in the
petrochemical industry alone are
estimated at $20 billion per year. In
addition to avoiding downtime,
damage, injury and environmental
emissions, the lost “opportunity cost”
due to operators functioning at less
than peak effectiveness looms large.
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Modular Procedural Automation eBook 14
Identifying MPA Opportunities
As with any engineering project, time spent on defining the scope on the front end
will pay off later in the project. But based on the experience gained by executing
thousands MPA projects, there are some additional details that should be
considered before starting with MPA. In this chapter we will share some of these
‘lessons learned’ and help you with identifying the top MPA candidates at your
plant or manufacturing facility.
Chapter 4
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What are your MPA candidates?
15
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Modular Procedural Automation eBook 16
Implementing MPA
In the previous chapter we explained what to look for identifying MPA
opportunities. Next step is implementing MPA. An important lesson that MPA
vendors have learned is that if MPA is not made as easy as possible for operators,
then a project isn’t likely to be successful. As a result, operator friendly software is
important. In this chapter we will highlight a methodology for implementing MPA.
Chapter 5
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Modular Procedural Automation eBook 17
Summary and Next Steps
MPA helps you standardize and automate your procedures. It’s all about capturing
your best operators’ know-how and implementing that as a standard operating
procedure in your plant to guide all operators. Instead of having just a check-list
that you’re training your operators on, you should look to automate that wherever
possible to have the most reliable and consistent outcome. “With MPA implemented
it’s like having your most experienced operators on hand at all times.”
Chapter 6
A next step in your orientation towards a MPA
solution is a Consulting Site Visit. You can request
this consult from Yokogawa. It will include:
o Identifying opportunities for improvement (major
“pain” points)
o Methodologies and templates for:
Site visit pre-work
Plant walkthrough
Interview checklists with:
• Management
• Operations
• Other functions
Initial review meeting/ on-site report
o Assist in ROI calculations
o Prioritize and recommend best solutions
Consulting Site Visit Yokogawa systems provides Comparative
Effective Analysis (CEA) - a built-in system
performance monitor. Among the items that CEA
reports is which loops are in MAN mode most often
and which loops have the most operator changes
associated with them. These loops can be targeted
for modular procedural automation. These same
measures can be analyzed on other systems but it
takes more effort because most other systems either
do not automatically collect this data or it is not
reported in an easy to analyze format.
Yokogawa can work with customers to
configure their systems to collect key factors for
analysis and we can assist in guiding the customer to
focus on specific loops and in creating automation
modules for procedures that mimic operator action for
managing single loops and critical transitions.
Comparative Effective Analysis
What can Yokogawa do for you?
1. MPA is about improving production performance and safety
2. Use MPA to help make your plant more productive through consistent, safer operations.
3. Look for MPA applications:
• Safety & Environment issues.
• Lost Production opportunities
• PID Loops in Manual mode or with high operator changes
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Modular Procedural Automation eBook 18