2012 Honeywell Users Group EMEA. Sustain.Ability. Stefan Willenbrecht, Honeywell Control Performance Management in Large Scale Environments

Transcription

1 2012 Honeywell Users Group EMEA Sustain.Ability. Stefan Willenbrecht, Honeywell Control Performance Management in Large Scale Environments 1

2 What is (CPM)? CPM is an application to monitor and manage the performance of regulatory assets PID, APC Instruments, Analyzers and APC vendor-independent Runs in the background automatically on periodic basis Calculates metrics (KPIs) from historical process data per asset that allow for a performance rating 2

3 VISUALIZE CPM Reporting Features Web portal based visualization of control asset performance o Drill down plant hierarchy o Sort, filter and prioritize control assets o Trend and track their control performance Automated notification of impending control issues o Customizable workflow integration o Automated notification o Disposition escalation mechanism IDENTIFY 3

4 Business Value Complexity & Cost 1 15 ~ $ 0.5% 1.4% 0.8% 1500 ~ $ 1.5% Scale Ref: Brisk et al (2004) 4

5 throughput Value of Reduced Variability Can increase product quality and throughput Optimal operation point can reduce energy consumption and maintenance cost Identify Variability Reduce Variability Move Target Monitor & Sustain Process Constraint Optimal Performance $ Current Performance time 5

6 Value SP Sample Number PV Turn Data Into Knowledge Off-spec performance Controller is oscillating Raw Data Graph for DataSource1 PV, SP, OP, MODE 6

7 Typical CPM Project Typical Scale Example 1-3 Plants Loops 5-25 Users Typical Infrastructure 1 CPM server Includes data collector OPC DA Interface to OPC Server Typical Implementation Time 2-4 weeks CPM Server Control Performance Monitor Interfaces OPC DA Server 7

8 Scope A Case Study - Enterprise Wide Deployment Integration of Alarm Management and Loop Management Combination of continuous and batch process operations Need to publish KPI at the enterprise level Inclusion of overall system health monitoring 8

9 Enterprise Wide Deployment (1) Large Scale Site ~150 Plants ~200 ~ Loops 500+ Users Selected Infrastructure OPC DA 1 20 CPM Servers Domain Controller ESX host (1) Active Directory PIMS PIMS PIMS 20 virtual data collection servers IP.21 OPC DA Interface to PIMS 2 redundant Enterprise Servers Project Schedule 18 Month MTK TRANSFER Custimization needed using PI SDK / API PI LDAP Control CPM Performance Server (1) Monitor IP.21 CPM Enterprise Control Performance Monitor PI CPM Server (n) Control Performance CPM Server Monitor (1) PIMS PIMS PIMS 2 KPI SYNCHRONIZATION Custimization needed using synchronization service OPC DA OPC DA 1 OPC HDA PHD Firewall ESX host (n) MTK TRANSFER Custimization needed using PI SDK / API PHD 9

10 Enterprise Wide Deployment (2) ESX host (1) Large Scale Site ~150 Plants ~200 ~ Loops 500+ Users Selected Infrastructure 20 CPM Servers 20 virtual data collection servers OPC DA Interface to Firewall PIMS 2 redundant Enterprise Servers Project Schedule 18 Month OPC HDA ESX host (n) Domain Controller CPM Enterprise Active Directory LDAP Control CPM Performance Server (1) Monitor ESX host (1) Control Performance Monitor KPI SYNCHRONIZATION 2 Custimization needed using synchronization service OPC HDA CPM Server (n) Control Performance CPM Server Monitor (1) ESX host (n) Firewall MTK TRANSFER OPC DA 1 Custimization needed using PI SDK / API PIMS PIMS PIMS IP.21 PI PHD 10

11 Enterprise Wide Deployment (3) Large Scale Site ~150 Plants Control CPM Performance Server (1) Monitor ~ ~ Loops 500+ Users Selected Infrastructure 20 CPM Servers 20 virtual data collection servers OPC DA Interface to PIMS 2 redundant Enterprise Servers Project Schedule 18 Month CPM Server (n) Control Performance CPM Server Monitor (1) Domain Controller Active Directory LDAP Control CPM Performance Server (1) Monitor ESX host (1) CPM Enterprise Control Performance Monitor KPI SYNCHRONIZATION 2 Custimization needed using synchronization service OPC HDA CPM Server (n) Control Performance CPM Server Monitor (1) ESX host (n) Firewall MTK TRANSFER OPC DA 1 Custimization needed using PI SDK / API PIMS PIMS PIMS IP.21 PI PHD 11

12 Enterprise Wide Deployment (4) Large Scale Site Domain Controller ~150 Plants Active Directory LDAP ~200 ~ Loops 500+ Users Selected Infrastructure 20 CPM Servers 20 virtual data collection servers OPC DA Interface to PIMS 2 redundant Enterprise Servers Project Schedule 18 Month CPM Enterprise Control Performance Monitor 2 KPI SYNCHRONIZATION Domain Controller CPM Enterprise Active Directory LDAP Control CPM Performance Server (1) Monitor ESX host (1) Control Performance Monitor KPI SYNCHRONIZATION 2 Custimization needed using synchronization service OPC HDA CPM Server (n) Control Performance CPM Server Monitor (1) ESX host (n) Firewall MTK TRANSFER OPC DA 1 Custimization needed using PI SDK / API PIMS PIMS PIMS IP.21 PI PHD 12

13 Enterprise Wide Deployment (5) Large Scale Site ~150 Plants ~200 ~ Loops 500+ Users Selected Infrastructure 20 CPM Servers 20 virtual data collection servers OPC DA Interface to PIMS 2 redundant Enterprise Servers Project Schedule 18 Month Domain Controller CPM Enterprise Active Directory LDAP Control CPM Performance Server (1) Monitor ESX host (1) Control Performance Monitor KPI SYNCHRONIZATION 2 Custimization needed using synchronization service OPC HDA CPM Server (n) Control Performance CPM Server Monitor (1) ESX host (n) Firewall MTK TRANSFER OPC DA 1 Custimization needed using PI SDK / API PIMS PIMS PIMS IP.21 PI PHD 13

14 Project Challenges And Solutions (1) Need for configuration work necessary for / TaiJi PID Tuning / Alarm Manager / OPC Servers Requires configuration automation to speed up the deployment process and decrease system maintenance 14

15 Project Challenges And Solutions (2) Alarm Manager Control Performance Monitor OPC Server Configuraton OPC Client Configuraton 15

16 Project Challenges And Solutions (3) Number of interfaces to be connected to: Alarm & Event input streams Real time process data Reduce interface types to standardized ones Process Data: OPC DA (from PIMS systems) Event Data: OPC A&E, TXT OPC DA 1 MTK TRANSFER Custimization needed using PI SDK / API PIMS PIMS PIMS IP.21 PI PHD 16

17 Project Challenges And Solutions (4) PIMS Configuration Configuration Alarm Manager Control Performance Monitor OPC Server Configuraton OPC Client Configuraton 17

18 Project Challenges And Solutions (5) CPM/AM System to represent the real asset hierarchy No plant-specific asset hierarchy One master for the full system Creation of interface to SAP Online hierarchy synchronization with SAP 18

19 Project Challenges And Solutions (6) PIMS Configuration Configuration Asset Hierarchy Alarm Manager Control Performance Monitor OPC Server Configuraton OPC Client Configuraton 19

20 Project Challenges And Solutions (7) User Management in MS Active Directory Single configuration location for client to manage user access Creation AD Reader / Profile Manager services Create Groups / Users and access rights on distributed system in various products Synchronize all configuration against AD changes 20

21 Project Challenges And Solutions (8) PIMS Configuration Configuration Asset Hierarchy User / Override Configuration Alarm Manager Control Performance Monitor OPC Server Configuraton OPC Client Configuraton Groups & Users Access Permissions 21

22 Project Challenges And Solutions (9) Central storage of CPM/AM configuration Distributed system, but central store Support for workflow process between client and Honeywell personnel Creation of Deployment Database and UI to store Hierarchy, CPM and AM configuration User and access rights management 22

23 Deployment Database Principle PIMS Configuration Configuration Asset Hierarchy User / Override Configuration Deployment DB Alarm Manager Control Performance Monitor OPC Server Configuraton OPC Client Configuraton Groups & Users Access Permissions System Health Monitor 23

24 Project Challenges And Solutions (10) Batch plants to be monitored Typical batch parameters (e.g., product name, batch number, run time) to be included in the analysis Development of CPM for Batch extension Asynchronous execution of analysis triggered by batch end Batch start / end detection by PIMS tag or proprietary Batch Interface 24

25 Project Challenges And Solutions (11) Interface to MES System Expose CPM/AM KPIs to MES layer via HTTP/SOAP Creation of KPI Web Service Distributed system to read from source servers Buffer on separate server to serve highresolution short-time queries 25

26 Project Challenges And Solutions (12) Health monitoring of complex distributed system Various components to monitor for each product and server Use of System Health Monitor Distribute application doing local checks Root of application creates event in Alarm Manager Reporting of issues in Alarm Manager and per notification 26

27 System Health Monitor Principle Distributed over systems / machines involved in overall infrastructure Each machine hosts one SHM instance Central storage of check results as alarms in Alarm Manager Root instance of SHM sends data to A&E Collector via TCP Leverages all AM reporting functionality Can make use of emergency notification and escalation methods (Notification Manager) TCP single port TCP single port PIMS Server AM/CPM Server 1 TCP single port Interfaces TCP single port AlarmManager DB TCP single port Enterprise Server Enterprise DB AM/CPM Server n PIMS Server TCP single port Interfaces 27

28 Project Challenges And Solutions (12) Reporting on enterprise level (distributed large scale systems) How to display data of a distributed system in one report? Where to find detailed data on a distributed system? Creation of Enterprise KPI Server Management level reporting (using CPM report engine ) Central point of entry for all individual plant servers KPIs of various source systems in one view Redundancy through load balancing of two identical servers 28

29 Enterprise KPI Server Principle Site A HQ Aggregated results are transferred to central instance periodically User A Site C Site B User C Data is aggregated locally for hierarchy assets User B 29

30 Reporting Examples (1) Enterprise Hierarchy Enterprise hierarchy contains only high level views Reports are aggregates on available levels On click of lowest level in the enterprise hierarchy, users are routed to local server 30

31 Reporting Samples (2) 7d Roll Up Table CPM KPIs AM KPIs 31

32 32 Reporting Samples (3) 7d Tree Map

33 On-going Support Needs Product and Application Specific Support Clear Definition Training for continuity in support resources Tiered Support Model Shared responsibilities between Honeywell and Client teams Regular review of support Quarterly report Bi-annual meetings of application owners Extended support Monthly health check service Identification of application improvement 33

34 Advantages (1) Configuration Standard! A defined standard for a CPM configuration reduces effort for Setting up a new system Changing configuration of an existing CPM system Training personnel to use and administer the CPM system Identifying a problem in case a CPM system doesn t work properly Maintaining a CPM system But... Keeping to a standard manually demands a stern discipline Might make configuration more complex for individuals at first sight Automation based on defined standards and central store Speeds up deployment Allows for easier maintenance 34

35 Advantages (2) = Best Practices 3rd level Dedicated historian for process data reading from PIMS systems Escalation 2nd level Seamless integration into Manager Escalation existing infrastructure Escalation for Performance Escalation Prevent archive overload of existing PIMS systems Plant for Repairs Integration Manager into customer by workflow Mandatory to leverage CPM s findings Monthly s ARC Benchmarks (PDF Attachments) Health checks and support Investigate / Provide Info Online monitoring of system Weekly Investigate health / essential Support needs to be appropriate to system size Shift Supervisor CPM is no magic bullet Instrumentation Valve Condition / Instruments Monthly Reports Reports CPM Weekly s Pending List & Overdue Controllers Change Status SUPPORT for Repairs 2nd level for Repairs 1st level Investigate / Change Status Weekly Reports of Issues Control Optimization Manager 1st level Escalation for Performance Technical Services E & I A tool does not replace engineering knowledge DELEGATE It complements it and eliminates menial tasks 35

36 36 Question & Answer

37 Thank You