Levels of Procedural Automation

Levels of Procedural Automation - Survey Introduction

Procedural automation in both batch and continuous processes has been deployed to improve operational performance by reducing human error associated with both routine and non-routine tasks. These techniques are defined in the ISA 88 and emerging ISA 106 standards. This survey is being conducted to evaluate the various levels of procedural automation which are currently deployed in the process industries. Based on responses to the survey an analysis will be performed to determine the current state of procedural automation deployment, define areas of opportunity and the estimate the interest level to further invest in these technologies.

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1. What is your preferred choice of automation technique? <select one>

Operator manually controls the process

Basic regulatory loop control with manual operator execution of discrete procedures

Basic regulatory control with computer assisted procedural execution

Advanced regulatory control with basic procedure execution with the controller system

Advanced regulatory control with advanced automated procedural execution.

Comment

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2. What is your philosophy on level of procedural automation? <select one>

Process sequencing should mainly be operator controlled locally with standard operating procedures

Operator should manually execute process steps with limited computer oversight

Process should be modestly automated with computer assisted procedural control solution

Process procedures should be significantly automated for selective units based on quality or productivity importance.

All modes of operation are fully automated for all units within a process facility including integrated smart alarming and advance HMI navigation and troubleshooting.

Comment

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3. What is your current level of automated procedures? <select one>

Most manual operations are commanded by the field operators

Several operations are commanded by a combination of field operator with board operator second level confirmation

Some manual operations are executed in the field but primary modes of operation are commanded by the board operator

Many procedures are automated within a process control solution including HMI graphics, Smart alarming, and advanced procedural control schema

Majority of procedures are fully automated having minimal field manual operations for non-routine activities

Comment

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4. Describe your typical plant process

Batch

Continuous

Hybrid

Discrete

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5. What is a typical plant Total IO Count?

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6. Given a typical plant Total IO count, What is your Digital Input (DI) percentage?

Percent

100

Clear

i We adjusted the number you entered based on the slider’s scale.

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7. Given a typical plant Total IO count, What is the Digital Output (DO) percentage?

Percent

100

Clear

i We adjusted the number you entered based on the slider’s scale.

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8. Given a typical plant Total IO Count, What is the Analog Input (AI) percentage?

Percent

100

Clear

i We adjusted the number you entered based on the slider’s scale.

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9. Given a typical plant Total OI Count, What is the Analog Output (AO) percentage?

Percent

100

Clear

i We adjusted the number you entered based on the slider’s scale.

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10. Process Performance Driven HMI <select one>

Majority of the control application have no graphic displays or field local only.

Basic HMI graphics with limited abnormal situation management principles are deployed. Operational state of individual devices are available.

Enhanced HMI graphics indicating operational status (modes of operation) of equipment groups

Operational status based on mode of operation of each unit employed. Event contextualized unit performance based on “time in operating state” is provided with First-Out indication of abnormal conditions.

Hierarchical graphical designs are implemented for all process levels including process cell unit and equipment module level. Abnormal operational performance can be navigated based on process state.

Comment

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11. Process Sequencing and Modes of Operation <select one>

Few field devices are sequentially computer controlled; Hardcopy SOP’s only are used to define the sequence of control actions.

Some of the field devices are sequentially controlled by a procedural automation solution. Control application configuration is limited to basic control functions, alarms and interlocks.

Several of the field devices are sequentially controlled by various means. Some advanced procedural control schemes and sequences are implemented in alignment with ISA88/106 standards.

Many processes configured to ISA88/106 guidelines. Limited used of procedural interlocking based on modes of operation.

Most of processes are configured to ISA88/106 guidelines. All devices / equipment /units defined as business critical , are sequentially controlled based on modes of operation. Extensive use of interlocking based on modes of operation.

Comment

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12. Operating Mode based Smart Alarming <select one>

Limited graphical display of alarming, Alarms indicated by local panel annunciators.

Alarms are annunciated thru an HMI. Alarm is an attribute of an IO point. Operator routinely overwhelmed with meaningless or nuisance alarms.

Routine alarms rationalized for most frequent offenders. Operator occasionally overwhelmed by alarm showers during an abnormal event. ISA-18 alarm frequency guidelines met only some of the time.

Alarms are enabled by active mode of operation. Infrequent nuisance alarms eliminated for the most part. ISA-18 alarm frequency guidelines met most of the time

All process alarms are enabled by active modes of equipment operation. Alarm rates per hour per operator are consistently below ISA-18 guidelines.

Comment

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13. Unit to Unit Coordination Control <select one>

No coordination control of process. Routinely experience process trips due to unavailability of upstream and downstream process equipment or utilities. Requires engineering intervention.

Limited equipment performance coordination managed manually by operator. Frequently unintended process trips are mitigated by operator response on an ad hoc basis.

Some automated equipment coordination control strategies within a single unit operation are employed to detect and alert a pending unit trip.

Several unit to unit process state driven coordination control schema are employed to mitigate a partially impaired process cell and initiate recover semi-automatically.

Extensive process cell to process cell coordination strategies extensively deployed to balance / maintain overall operational performance by mitigating plant imbalances unit to unit with automated self-healing mechanisms deployed.

Comment

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14. Describe your company <select one>

Owner / Operator

Original Equipment Manufacturer

Engineering Services provider

Systems Integrator / Solutions provider

Consulting

Other (please specify)

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15. Would you consider higher levels of procedural automation to improve operational performance?

Not a consideration at this time

Slightly interested but would require more technical information on possible solutions or would need to understand the value case

Moderately interested and am piloting state based automation solutions

Highly interested having completed pilots and currently developing best practices templates preparing for broad implementation.

Broadly deploying state based automation solutions

Comment

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16. In which industry do you work / service <select one>

Chemical / Plastics

Hydrocarbon / Petroleum

Food / Beverage

Consumer Packaged Goods

Pharma / Specialty Chemicals

Discrete manufacturing

Other (please specify)

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17. What is your span of responsibility within your company.<select>

A single operating unit

A single site with multiple units

A business unit with multiple regions and sites

Global responsibility for all sites within a company

Research and Development

Other (please specify)

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18. In which geography does your company participate? <select all that apply>

Europe

Middle East / Africa

North America

Latin America

Asia - Pacific

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19. How big is your company based on number of employees? <select>

<500

500-1000

1000-3000

3000-10,000

>10,000

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* 1. What is your preferred choice of automation technique? <select one>

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* 2. What is your philosophy on level of procedural automation? <select one>

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* 3. What is your current level of automated procedures? <select one>

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* 4. Describe your typical plant process

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* 5. What is a typical plant Total IO Count?

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* 6. Given a typical plant Total IO count, What is your Digital Input (DI) percentage?

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* 7. Given a typical plant Total IO count, What is the Digital Output (DO) percentage?

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* 8. Given a typical plant Total IO Count, What is the Analog Input (AI) percentage?

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* 9. Given a typical plant Total OI Count, What is the Analog Output (AO) percentage?

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* 10. Process Performance Driven HMI <select one>

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* 11. Process Sequencing and Modes of Operation <select one>

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* 12. Operating Mode based Smart Alarming <select one>

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* 13. Unit to Unit Coordination Control <select one>

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* 14. Describe your company <select one>

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* 15. Would you consider higher levels of procedural automation to improve operational performance?

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* 16. In which industry do you work / service <select one>

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* 17. What is your span of responsibility within your company.<select>

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* 18. In which geography does your company participate? <select all that apply>

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* 19. How big is your company based on number of employees? <select>

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* 20. Would you be interested in a follow up discussion – < enter Email address>

1. What is your preferred choice of automation technique? <select one>

2. What is your philosophy on level of procedural automation? <select one>

3. What is your current level of automated procedures? <select one>

4. Describe your typical plant process

5. What is a typical plant Total IO Count?

6. Given a typical plant Total IO count, What is your Digital Input (DI) percentage?

7. Given a typical plant Total IO count, What is the Digital Output (DO) percentage?

8. Given a typical plant Total IO Count, What is the Analog Input (AI) percentage?

9. Given a typical plant Total OI Count, What is the Analog Output (AO) percentage?

10. Process Performance Driven HMI <select one>

11. Process Sequencing and Modes of Operation <select one>

12. Operating Mode based Smart Alarming <select one>

13. Unit to Unit Coordination Control <select one>

14. Describe your company <select one>

15. Would you consider higher levels of procedural automation to improve operational performance?

16. In which industry do you work / service <select one>

17. What is your span of responsibility within your company.<select>

18. In which geography does your company participate? <select all that apply>

19. How big is your company based on number of employees? <select>

20. Would you be interested in a follow up discussion – < enter Email address>