Sustain.Ability. Stefan Secker, Honeywell Process Solutions Best Practices for Deployment of CPM, Loop Management Solution
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1 Sustain.Ability Honeywell Users Group Americas Stefan Secker, Honeywell Process Solutions Best Practices for Deployment of CPM, Loop Management Solution 1
2 What is Control Performance Monitor (CPM)? CPM is an application to monitor the performance of regulatory assets PID, APC Instruments, Analyzers DCS 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 IDENTIFY 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 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 1-3 DCS Loops 5-25 Users Typical Infrastructure 1 CPM server Includes data collector OPC DA Interface to DCS OPC Server Typical Implementation Time 2-4 weeks 7
8 A Case Study - Enterprise Wide Deployment Scope 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 Large Scale Site ~150 Plants ~200 DCS ~ 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 CPM Server (1) CPM Server (1) CPM Server (1) Control CPM Performance Server (1) Monitor Control Performance Monitor Control Performance Monitor Control Performance Monitor Operational Insight Operational Insight Operational Insight Operational Insight ESX host (1) OPC Desktop Historian OPC Desktop Historian OPC Desktop Historian OPC Desktop Historian Control Performance Monitor Operational Insight KPI SYNCHRONIZATION 2 Custimization needed using synchronization service OPC HDA CPM Server (n) CPM Server (1) CPM Server (1) Control Performance CPM Server Monitor (1) Control Performance Monitor Control Performance Monitor Control Performance Monitor Operational Insight Operational Insight Operational Insight Operational Insight ESX host (n) OPC Desktop OPC Desktop Historian OPC Desktop Historian OPC Desktop Historian Historian Firewall MTK TRANSFER OPC DA 1 Custimization needed using PI SDK / API PIMS PIMS PIMS IP.21 PI PHD DCS DCS DCS 9
10 Project Challenges And Solutions (1) Need for configuration work necessary for Control Performance Monitor / TaiJiPID Tuning / Alarm Manager OPC Desktop Historian / OPC Servers Users/Groups and Access Rights Creation of configuration automation tools to speed up deployment process significantly 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 10
11 Project Challenges And Solutions (2) 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 Central store 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 11
12 Deployment Database Principle PIMS Configuration DCS 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 12
13 Project Challenges And Solutions (3) 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 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 13
14 Project Challenges And Solutions (4) 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 high-resolution short-time queries 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 14
15 System Health Monitor 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 15
16 Project Challenges And Solutions (5) 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 16
17 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 17
18 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 18
19 Reporting Samples (2) 7d Roll Up Table CPM KPIs AM KPIs 19
20 20 Reporting Samples (3) 7d Tree Map
21 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 21
22 Lessons Learned (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 22
23 Lessons Learned (2) = Best Practices Dedicated historian for process data reading from PIMS systems Seamless integration into existing infrastructure Prevent archive overload of existing PIMS systems Integration into customer workflow Mandatory to leverage CPM s findings Health checks and support Online monitoring of system health essential Support needs to be appropriate to system size CPM is no magic bullet A tool does not replace engineering knowledge It complements it and eliminates menial tasks 23
24 24 Question & Answer
25 25 Thank You
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