© copyright 2005 abb. all rights reserved. - 1 - with abb’s system 800xa sustaining an alarm...
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Sustaining an Alarm Management Strategy
with ABB’s System with ABB’s System 800xA800xA
Presented by Roy TannerSystem 800xA Marketing Manager
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Facts about ABB
Headquarters: Zurich, Switzerland
About 104,000 employees in around 100 countries
Orders in 2005: $23.6 billion
Revenues in 2005: $22.4 billion
Research and Development in 2005: $960 million
Listed on Stockholm, Swiss & New York exchanges; traded on virt-x
A leading power and automation technology company with strong market positions in its core businesses
Core business organized into 5 divisions; Power Products, Power Systems, Automation Products, Process Automation, and Robotics
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Divisional Structure and Portfolio
Robots, peripheral devices and modular manufacturing solutions for industry
Process Automation
Sales: $5.0 billion
Control systems and application-specific automation solutions for process industries
Substations, FACTS, HVDC, HVDC Light, power plant & network automation
Power Systems
Sales: $4.0 billion
Robotics
Sales: $1.7 billion
Transformers, high- and medium-voltage switchgear, breakers,automation relays
Power Products
Sales: $6.4 billion
Automation Products
Sales: $5.9 billion
Low-voltage products, drives, motors, power electronics, and instrumentation
* Estimated 2005 revenues, Including internal sales to other divisions
Market-leading positions in most key product areas Integrated solutions for grid reliability, productivity and energy efficiency Robust global value chain to serve established and emerging markets Extensive global network of value-added channel partners
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Reduces time from decision to action
Optimizes plant asset availability and performance
Integrates information for improved visibility
Improves batch consistency, quality, and cycle time
Uses proven solutions based on industry knowledge and experience
Extends installed system capabilities through seamless evolution
System 800xA Extended Automation
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Traditional Automation
Instrumentation& Drives
“Traditional” DCS/OCS
InformationManagement
Asset Optimization
S88 ProductionManagement
ProgrammableLogic Control
Advanced Control
Motor ControlCenters
Safety
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System 800xA
A single operations, engineering and information management environment for
an Extended Automation scope
Redefining the Automation System Standard
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Industrial IT Technology Partnership
Reduced Total Cost of OwnershipReduced Total Cost of Ownership
Increased Production OutputIncreased Production Output
Improved SafetyImproved Safety
Industrial IT solutions build upon the 800xA extended automation system with integrated devices and 3rd party software applications to deliver Continuous Improvement for our customers.
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Many products in each category are currently Certified as Industrial IT Enabled against System 800xA.
Industrial IT Technology PartnershipIndustrial IT solutions leverage best-in-class products from ABB and partners to deliver value in every solution area.
Infrastructure components Hirschmann switches Cisco switches MOXA switches OnTime switches Phoenix switches Dell PC / Server HP PC / Server IBM PC / Server IBM Blade Server
Hardware TDC3000 Connect SafeGuard Connect PlantGuard Connect ABB INSUM Metso Valve Positioner IIT Training Simulation Stratus FT Servers
Software800xA Integrated functions
Merriam Device MgmtSystem (Calibration) Real Time ProductionIntelligence (OEE) MRO Maximo CMMS SAP/PM CMMS IFS CMMS AES SmartPlant (InTools) Matrikon ProcessGuard
Intelligent Devices All devices in the device
integration library >20 HART types >20 FF types >12 Profibus types
ABB and other vendors Fisher Rosemount Samson Westlock Flowserve Siemens
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What is alarm management?
It is not a product…
“Work process by which alarms are engineered, monitored, and managed to ensure safe, reliable operations”
Spans multiple departments, requires everyone’s buy in, and part of everyday operational practices
C/O Matrikon Inc.
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How Are These Objectives Achieved?
Alarm Philosophy
Benchmark &Assessment
Alarm Rationalization
Implementation &Execution
ContinuousImprovement
Maintenance
C/O Matrikon Inc.
By following a proven process
By using best in class technology to match project requirements
By using standards and good practice guides
Sustaining an alarm management program often presents the biggest challenge
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Sustaining the Strategy
C/O Matrikon Inc.
Alarm Loading / Plant Reliability Indicator
Bad Actors
RationalizationWith Alarm Hiding
Can degrade over time
Typical results with DCSsMaximum # Alarms per Hr
Ave
rage
# A
larm
s pe
r H
r
600060060
600
60
6 X
Impossible
Overloaded
Reactive
StableRobust
PredictiveBad ActorsNuisance Alarms
Alarm RationalizationDynamic Alarm
Handling
Degradation over Time
The ABB-Matrikon partnership is focused on ensuring results are easily sustained!
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Continuous Improvement Challenges
EEMUA #191 & ISA RP18.2 outline best practices
Alarm management involves all departments, how can you ensure this is an on-going priority for everyone?
Operations
“ No tools to verify key problems and then take action” “ I don’t want another screen to look at.”
Engineering “I follow good change management processes, but I don’t know if the
current DCS matches engineered values” “I need real-time access to CURRENT information on DCS inhibited
alarms to verify and approve” Maintenance / DCS Technicians
“Too much to do already! Are these work orders valid/important?” “I want a system that is easy to maintain and administer”
Management “I am losing experienced operators, how can we leverage their
experience?”
Personnel are overworked. In order to sustain an alarm strategy, we need
to streamline the process!
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System 800xA and ProcessGuard
ABB System 800xA- Extended Automation system
built for continuous improvement and risk reduction
- Built with Industrial IT technology that consolidates and filters information
- IIT Technology Partnership program to connect and utilize best in class offerings
Matrikon’s methodology & technology combined with ABB’s 800xA Real-Time Alarm Technology is the first complete alarm management solution!
Matrikon AlarmMOCCA
- Alarm management of change configuration assistant
- Provides a safe environment through improving change management practices
- Stores parameters, change logs, difference reporting from actual DCS values
- Contains alarm definitions, cause, effect, and recommended action information which can assist operations
Matrikon Process Guard
- Comprehensive alarm and event analysis package that simplifies the benchmarking process
- Provides a consistent alarm management program throughout the entire lifecycle and enterprise
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Industrial IT VisionIndustrial IT is ABB’s commitment to open interconnectivity of Automation and Power solutions and services, leveraging the ABB portfolio, 3rd party products and the relevant standards.
Industrial IT enables ABB to provide three core values to our customers: Reduced Total Cost of Ownership (TCO)
Increase Production Output
Reduced Risk and Improved Safety
Industrial IT technology enables interoperability of applications: Direct access to information
Template based connectivity
Single window operator environment
ABB System 800xA
Matrikon ProcessGuard
AE Messages viaPrinter port (Serial)
Printer port (TCP/IP)OPC AE (SV 5)
Text File (Report)ODBC (Info Mgt)
Matrikon Matrikon AlarmInsight AlarmInsight for System 800xAfor System 800xA
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Matrikon AlarmInsight Provides a complete alarm management solution …by providing
a certified, pre-tested, integrated system components
Matrikon AlarmInsight Aspect System Direct, contextual access to ProcessGuard
Alarm Analysis and AlarmMOCCA reports to streamline workflows
Direct access to Operator Assistance report giving cause, effect, and recommended action data for operations consistency and decision support.
Easy to implement (no programming needed) to reduce engineering and reduce maintenance.
AECollector able to be loaded on System800xA clients to reduce time to commission.
Combined desktop tools to improve root cause analysis (offered as a service from Matrikon)
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Functional Structure – AI Report Aspect
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Operator view – AI Report Aspect
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Summary
Alarm Management is more than a product
System 800xA has features that help implement and maintain an alarm management strategy such as Alarm Hiding and effective navigation, organization and presentation.
Matrikon’s ProcessGuard has features that
Industrial IT Enabled Matrikon AlarmInsight helps sustain an alarm management strategy