Intuitive Operator Support by new Process Visualization Dirk Stevens, Power Generation; Dr. Martin Hollender, Moncef Chioua, Corporate Research Center Intuitive Operator Support by new Process Visualization © ABB 20.11.2018 Enter filename via "View - Header and Footer...". Apply to all. | 1

Agenda Current Status System 800xA Optimized Displays System 800xA Alarm Management Summary © ABB 20.11.2018 Enter filename via "View - Header and Footer...". Apply to all. | 2

„I would have liked to have thrown away the alarm panel „I would have liked to have thrown away the alarm panel. It wasn't giving us any useful information.” Craig Faust, operator of the Three Mile Island Nuclear Power Plant during the official analysis of the TMI accident © ABB 20.11.2018 Enter filename via "View - Header and Footer...". Apply to all. | 3

Typical number of alarms Petro- chemistry Power production * Soucre: Engineering Equipment and Materials User’s Association EEMUA* Oil & Gas others Alarms per day (Average) 144 1200 1500 2000 900 Persisting alarms (Average) 9 50 100 65 35 Peak value per 10 min. 10 220 180 350 180 Average/ 10 min. Interval 1 6 9 8 5 Distribution % (low/middle/high) 80/15/5 25/40/35 25/40/35 25/40/35 25/40/35 © ABB 20.11.2018 Enter filename via "View - Header and Footer...". Apply to all. | 4

Results of an ABB field study in control centers Often the symptoms were analyzed, without looking for the real cause Troubleshooting often by try and error Most important method for troubleshooting: „Is somebody familiar with this problem?“ Operators must remain in the loop for all current tasks Complex long lasting tasks (for more than one shifts) are not supported by many systems © ABB 20.11.2018 Enter filename via "View - Header and Footer...". Apply to all. | 5

Challenges in the operation of power plants Maximization of availability and performance High demands on efficiency and environmental protection More flexible operation modes, to balance the variations caused by the renewable power production Scope of the used fuel © ABB 20.11.2018 Enter filename via "View - Header and Footer...". Apply to all. | 6

Challenges in the operation of power plants Modern power plants are highly automated but nevertheless the operator must have the possibility to build up and to extent his competence in order to control unforeseen situations detect and resolve upcoming problems as early as possible © ABB 20.11.2018 Enter filename via "View - Header and Footer...". Apply to all. | 7

System 800xA Optimized Displays and Alarm Management Optimized spatial fixed and always visible large-screen displays Counteract the “keyhole effect” Usage of pattern recognition abilities of the operators Common basis for team discussions (Early –) detection – understanding - action Optimization of the alarm system The operators are able to use the alarm system more efficiently Important alarms do not disappear in an alarm flood The operators are supported by an alarm database © ABB 20.11.2018 Enter filename via "View - Header and Footer...". Apply to all. | 8

Mass data displays Features Systematic approach provides a good overview Spatial fixed and always visible overview Usage of high-capacity pattern recognition abilities of the operators Challenge Efficient calibration (Which values are equivalent to the angles 90°,0°,-90°) Under normal conditions a regular and smooth pattern should be displayed © ABB 20.11.2018 Enter filename via "View - Header and Footer...". Apply to all. | 9

Calibration of mass data displays 5 4 3 frequency value Calibration Mainly automated on the basis of historical values Definition of multiple typical steady modes Recording of histograms for each mode Generation of parameters © ABB 20.11.2018 Enter filename via "View - Header and Footer...". Apply to all. | 10

Histogram for various process modes © ABB 20.11.2018 Enter filename via "View - Header and Footer...". Apply to all. | 11

Software Architecture System 800xA Process history Steady State Fingerprint Editor Detection of process failures Selected values Calibration parameter State detection Process value normalization Selection and grouping Definition of process modes Selection of time intervals fine tuning Quality control Visualization © ABB 20.11.2018 Enter filename via "View - Header and Footer...". Apply to all. | 12

Typical number of alarms Petro- chemistry Power production * Soucre: Engineering Equipment and Materials User’s Association EEMUA* Oil & Gas others Alarms per day (Average) 144 1200 1500 2000 900 persisting alarms (Average) 9 50 100 65 35 Peak value per 10 min. 10 220 180 350 180 Average/ 10 min. Interval 1 6 9 8 5 Distribution % (low/middle/high) 80/15/5 25/40/35 25/40/35 25/40/35 25/40/35 © ABB 20.11.2018 Enter filename via "View - Header and Footer...". Apply to all. | 14

Alarm Management according to EEMUA 191 Alarm Management Process Source: EEMUA 191 Suggestions for improvement Change management Implementation Reconciliation with standards Data collection Analysis © ABB 20.11.2018 Enter filename via "View - Header and Footer...". Apply to all. | 15

Measure Catalog for the Alarm Management Alarm structure Definition of an alarm concept Alarm database with change management Alarm priorities Definition operation modes Process scenarios Failure scenarios Definition of alarms group Definition of alarm suppression logic for alarm groups for operation modes © ABB 20.11.2018 Enter filename via "View - Header and Footer...". Apply to all. | 16

System 800xA Alarm Management Analysis functions according to EEMUA 191 Allocation of alarm priorities Ranking list: Alarm list sorted by the frequency of the alarms Average number of alarms divided by the maximum number of alarms per hour (EEMUA 191) Alarm management reports © ABB 20.11.2018 Enter filename via "View - Header and Footer...". Apply to all. | 17

System 800xA Alarm Management Key Performance Indicator (KPI) KPI´s are used as a basis for continuous improvements © ABB 20.11.2018 Enter filename via "View - Header and Footer...". Apply to all. | 18

System 800xA Alarm Management Alarm Hiding Alarm Bands Alarm List Hidden Alarm List Alarm Hiding Definition of alarm suppression logic for alarm groups for operation modes Hidden alarms are displayed exclusively in the Hidden Alarm List Reduction of the active alarms (which need an operator action) © ABB 20.11.2018 Enter filename via "View - Header and Footer...". Apply to all. | 19

System 800xA Alarm Management Alarm Shelving Shelve Alarm The “Shelving” function defers alarms temporarily e.g. due to maintenance activities A “shelved” alarm will be active again after an adjustable time period © ABB 20.11.2018 Enter filename via "View - Header and Footer...". Apply to all. | 20

Role based alarm handling Many alarms are only dedicated to a special group of operators The runtime of a device has accumulated up to a configured limit A switchover alarm to a redundant device (e.g. pump) A hard disk allocation is near to the capacity limit These alarms should be sent directly to their target group (e.g. maintenance group) and should not burden the process operators In System 800xA each target group can get optimal alarm list extracts by extended alarm filtering possibilities © ABB 20.11.2018 Enter filename via "View - Header and Footer...". Apply to all. | 21

Alarm Database Continuous improvement of the alarm system © ABB 20.11.2018 Enter filename via "View - Header and Footer...". Apply to all. | 22

Summary Highly automated power plants may have the problem, that the operator looses the process overview (98 % routine + 2 % stress during failures). System 800xA provides all functionality to implement the requirements of EEMUA 191 provides with a new process display functionality and alarm management functions high efficient means to the operator for an optimum control of a power plant and an early detection of upcoming problems. © ABB 20.11.2018 Enter filename via "View - Header and Footer...". Apply to all. | 23