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NOV-DEC 2017

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20 INTECH NOVEMBER/DECEMBER 2017 WWW.ISA.ORG PROCESS AUTOMATION provide the required solution. Data from all plants is consolidated in a single cloud-based historian via a se - cure and reliable data transfer method. For alarm and events data, the historian collects process data and alarms and events from each plant's control sys - tem. The solution enables alarms and events to be collected and monitored for each plant, and includes report gen - eration and key performance indicator (KPI) data for further analysis from the centralized control center. PID loop performance and alarms and events are displayed in a combined Web-based dashboard, providing a sin - gle display of key data for each site. The global plant management team now has a complete overview of each plant's status, and can analyze performance and identify operational improvement opportunities. Analyzing plant data across multiple sites lets organizations benchmark processes and equipment using real plant data for comparison and assess- ment. Additionally, this information helps establish best practice processes, which are applied across all sites to help identify and set attainable targets and evaluate overall performance. Measuring safety systems An ultra-deep- water production platform needed to monitor and record all safety KPIs and to record safety and perfor- mance informa- tion. It needed a repository for all trips and opera- tional statistics, covering all safety i n s t r u m e n t e d systems, to mea- sure actual per- formance against the original safety design. The historian, located off - shore, acquires data from the platform's DCS, safety instrumented systems, emer - gency shutdown systems, and fire and gas systems. The historian stores all rel - evant safety-related data. All essential safety-related KPIs and statistics are vali - dated and available in a single location. Without this solution, it would be very difficult and time consuming to consoli - date, view, and analyze this data. Safety systems need to have proof tests at various intervals to demonstrate that each component or subsystem is operational, such as a valve activation. The system can show that actual activa - tions were successful and can be used to verify that the safety system is working correctly while it is operating—elimi - nating the need for further proof tests requiring shutdown. This reduces the number of plant startups and shut - downs required for scheduled testing. This proof testing and safety trip data provides design input for layer of pro- tection analysis (LOPA) and safety case updates, showing the true demand rates and helping identify scenarios and the frequencies of events. For each safety loop, statistical data and reports illustrate the true demand placed on that loop over a number of years. This historical data has actual field demand rates, and can be used to validate the safety case against the original design assumptions that were based on calculations. More value Traditional historians were proprietary, closed systems used primarily to view and visually analyze process performance at a single site. Modern historians are open systems that work with any DCS or other data source, store data in open SQL Serv- er databases and across the world in the cloud, and make data available to anyone, anywhere—as long as they have the prop- er security credentials. Modern historians can also perform a variety of functions, such as alarm analy - sis, safety system verification, PID analy- sis, and energy monitoring. And instead of requiring companies to develop their own analysis software or hire data scien - tists, modern historians can be provided with or linked to specialized analysis ap - plication software. n ABOUT THE AUTHOR Wayne Matthews (Wayne.Matthews@ymx. yokogawa.com) is a computer science grad - uate who has worked for Yokogawa Marex for more than 20 years. He has a wealth of experience in the development and deploy - ment of manufacturing execution and plant information management systems. He has overseen the creation of a comprehensive portfolio of software solutions, particularly in alarm, safety, and production management. View the online version at www.isa.org/intech/20171202. RESOURCES Reinventing the Role of the SCADA Historian www.isa.org/reinventing-the-role-of-the- scada-historian ANSI/ISA-18.2-2016, Management of Alarm Systems for the Process Industries www.isa.org/management-of-alarm-systems- for-the-process-industries Plant Historians Deliver Insight and Improve Operations www.isa.org/plant-historians-deliver-insight- improve-operations Combined dashboard display Overview of site performance Data analysis and reporting Web-based application Site 1 Site 2 Site 3 Site 10 A&E Process RDS RDS RDS RDS A&E Process A&E Process A&E Process Exaquantum local data collector 1 Exaquantum local data collector 2 Exaquantum local data collector 3 Exaquantum local data collector 10 MANUFACTURING LOCAL DATA SERVERS CLOUD DASHBOARD SITES DISPLAY Alarm reporting and analysis (A&E data) Exaquantum data historian MDPro (process data) Alarm data display PID loop performance Figure 5. This cloud-based historian acquires data from five different types of control systems in 10 plants worldwide, and produces alarms and events and PID controller performance reports.

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