{"id":2450,"date":"2019-01-11T08:08:14","date_gmt":"2019-01-11T07:08:14","guid":{"rendered":"https:\/\/staging.blogs.yokogawa.de\/chemical-pharma\/uncategorized\/assistance-systems-4-retain-knowledge-and-drive-safely\/"},"modified":"2022-06-17T09:28:31","modified_gmt":"2022-06-17T07:28:31","slug":"assistance-systems-4-retain-knowledge-and-drive-safely","status":"publish","type":"post","link":"https:\/\/www.yokogawa.com\/eu\/blog\/chemical-pharma\/en\/assistance-systems-4-retain-knowledge-and-drive-safely\/","title":{"rendered":"Assistance systems \u2013 4. Retain knowledge and \u201cdrive\u201d safely"},"content":{"rendered":"<p>Parts 1 to 3 of our series addressed the subject of <a href=\"https:\/\/www.yokogawa.com\/eu\/blog\/chemical-pharma\/?p=7514\">\u201cAssistance Systems\u201d<\/a> in general, then took a look at <a href=\"https:\/\/www.yokogawa.com\/eu\/blog\/chemical-pharma\/?p=7871\">\u201cAdvanced Process \/ Model Predictive Control\u201d<\/a> before turning to the complex of issues referred to as <a href=\"https:\/\/www.yokogawa.com\/eu\/blog\/chemical-pharma\/de\/assistenzsysteme-3-wegweiser-vorausschauer\/\">\u201cDigital Twin, Real Time Optimization and MirrorPlant\u201d<\/a>.<\/p>\n<p>We learned that all of these assistance systems are designed to <strong>support<\/strong> or assist us with certain activities. Among other things, they do this by simultaneously <strong>capturing<\/strong> and <strong>evaluating<\/strong> a large number of <strong>variables<\/strong> and supplying us with the correct, current <strong>setpoint<\/strong>. Some systems relieve us of the burden of continuously having to respond to minor changes in order to keep the plant running <strong>stably<\/strong>. Always with the objective of <strong>improving efficiency<\/strong>, <strong>safety<\/strong> and <strong>availability<\/strong> in production.<\/p>\n<p>Today\u2019s assistance system is slightly different. It\u2019s more like an <strong>\u201celectronic driving instructor\u201d<\/strong>, who is constantly there to assist me with his experience and <strong>get me through safely<\/strong>, not only in tricky situations. He\u2019s a <a href=\"https:\/\/www.yokogawa.com\/solutions\/products-platforms\/solution-based-software\/optimization\/procedural-automation-exapilot\/\"><strong>driver assistance system<\/strong><\/a> in the truest sense of the word.<\/p>\n<h2>The standard operating procedure (SOP) \u2013 A help and a problem<\/h2>\n<p>Let\u2019s start by looking at the standard operating procedure (SOP). This is a document that exists for every plant. It describes how to start the plant up and shut it down again, how to run it in normal operation, how to move it to another operating point, etc. It should be noted in this connection that the SOP doesn\u2019t simply explain (at least in the best case) what I, as the plant operator, must do in the control room but also what must be done in cooperation with the field operators and others, for example opening valves manually during the startup process. All in all, it\u2019s a crucial document in.<\/p>\n<p>Unfortunately, there tends to be a snag \u2026 the SOP is usually only available in paper form. It isn\u2019t designed for interactive scenarios with the plant operator. This can easily lead to a situation like the following:<\/p>\n<p><strong>Plant operator:<\/strong>\u00a0<em>\u201cWhere is it? Is it even up to date, and where on earth is the section I need right NOW? That\u2019s the way my colleague did it last time but it doesn\u2019t say anything about that here\u201d.<\/em> And so on and so forth.<\/p>\n<p>Sometimes, you hit on a SOP that leaves you at a loss for words because about the only thing it tells you is that starting up is \u201ccomplicated\u201d (reality or satire?). What we can say, though, in a nutshell is that \u2026<\/p>\n<ul>\n<li>The SOP is not always up to date.<\/li>\n<li>Operator knowledge that has been built up over time is not documented in the SOP.<\/li>\n<li>\u201cPaper files\u201d provide suboptimal support in what is in any case a complex situation.<\/li>\n<\/ul>\n<p>What I have in mind and what I really want is this: first, an electronic SOP (eSOP) that makes it easy for me to stay up to date and document changes in a traceable manner. Second, once I\u2019ve got an eSOP, to make it available in a form where interaction is child\u2019s play, in short an interactive driver assistance system.<\/p>\n<h2>eSOP and automated driving system \u2013 One solution, many options<\/h2>\n<p><strong>4 distillation columns, 2 reactors, 1 crystallizer \u2026 the startup process is complex.<\/strong><\/p>\n<p>What\u2019s more, when starting up the reactors account must be taken of a so-called \u201cEx nose\u201d. Even though a detailed SOP exists, the startup times and results vary considerably. If we look over the shoulders of the plant operators, we can see that each one implements the SOP in a slightly different way. And every now and then, the startup path is too close to the Ex nose, so that the plant is shut down again. All in all, that isn\u2019t very satisfactory. It\u2019s something we need to focus on and the objective is clear:<\/p>\n<p><strong><img decoding=\"async\" class=\"wp-image-7800 alignleft\" src=\"https:\/\/www.yokogawa.com\/eu\/blog\/app\/uploads\/sites\/8\/2022\/06\/Exap-30-2-300x164.jpg\" alt=\"\" width=\"620\" height=\"339\" \/>To standardize the startup process and make it safer and more economical.<\/strong><\/p>\n<p>The <strong>solution<\/strong> we choose is a combination of an <strong>eSOP (electronic SOP) and an automated driving system<\/strong>. We\u2019re convinced by the results. There are far fewer variations in the column startup process and the <strong>startup time<\/strong> is <strong>one third shorter<\/strong> on average. Even more impressive is the <strong>amount of off-spec material<\/strong> during the startup. It\u2019s typically <strong>90% lower<\/strong>. Emergency shutdowns have been virtually eliminated while the reactors are starting up. Once again, the <strong>startup time<\/strong> has been <strong>reduced by one third<\/strong>, and at the end of it the reactor is operating at <strong>100% load<\/strong> rather than just 70%. This example from the German chemical industry has an <strong>ROI<\/strong> of well <strong>under a year<\/strong>.<\/p>\n<p>I\u2019d like to make one more point about complexity in this example. Approximately <strong>600 measuring points<\/strong> and <strong>800 manual interventions<\/strong> have to be considered during the startup. When I say manual interventions here, I\u2019m mainly referring to setpoint adjustments, manual operations, etc. The introduction of the assistance system results in <strong>4200 parameters<\/strong> and <strong>7500 different instructions<\/strong> being executed in the <strong>automated driving system<\/strong> during the startup. A lot of manual steps are still necessary in spite of all the automation.<img decoding=\"async\" class=\"wp-image-7726 alignright\" src=\"https:\/\/www.yokogawa.com\/eu\/blog\/app\/uploads\/sites\/8\/2022\/06\/Man-Op-by-Op-300x151.jpg\" alt=\"\" width=\"614\" height=\"309\" \/><\/p>\n<h2>eSOP &amp; driver assistance system \u2013 Principle &amp; implementation<\/h2>\n<h3>eSOP \u2013 More than just digitized paper<\/h3>\n<p>Let\u2019s begin by taking a look at the SOP. We\u2019re talking about more than simply digitizing a SOP that already exists here. As I mentioned earlier, SOPs frequently suffer from serious shortcomings. The following objectives are specified when writing an eSOP:<\/p>\n<ul>\n<li>Determine the actual condition of the plant and the control system as well as the current, related \u201coperating modes\u201d.<\/li>\n<li>Take account of all relevant players in these modes, namely control room, field and other personnel.<\/li>\n<li>Incorporate all of the knowledge built up by the operators in the past (control room, field, etc.).<\/li>\n<li>Establish an easy means of updating, where document management is an integral element.<\/li>\n<li>Be readily understandable and traceable.<\/li>\n<\/ul>\n<p>So far, you could be forgiven for thinking that the new eSOP is no more than an ordinary Word document. However, if that were the case, we\u2019d simply end up with old wine in new bottles. That\u2019s why we also need to set ourselves other goals:<\/p>\n<ul>\n<li>Make the eSOP interactively available to the operator<br \/>\n\u2013 As an electronic document (Word, PDF, etc.) in or at the PCS<br \/>\n\u2013 As a graphical, real-time \u201cnavigation\u201d system through a procedure, e.g. the startup*<\/li>\n<li>Take this one step further (based on the eSOP)<br \/>\n\u2013 As a graphical, real-time \u201cnavigation\u201d system <strong>AND<\/strong> active assistant during operation of the system**<br \/>\n\u2013 Ultimately enable procedures to be implemented completely independently, e.g. grade changes***<\/li>\n<\/ul>\n<p>* Driving instruction ** Driver assistance *** Automated driving system<\/p>\n<p>In order, therefore, for the eSOP to capture and retain the best operational knowledge, merely taking the existing SOP as a basis is not enough. <strong>Operator know-how<\/strong> and evaluations of <strong>log files<\/strong> are other useful <strong>sources<\/strong>. In the same way as we search for the \u201cgolden batch\u201d, we\u2019re now searching for the \u201cgolden mode\u201d, which we want to analyze and document as a procedure.\u00a0 In the meantime, this can also be partially automated.<\/p>\n<h3>From driving instruction to automated driving system \u2013 Using the eSOP interactively<\/h3>\n<p>When we discuss SOPs with the operators, one wish they express is that they should be <strong>rapidly and interactively available<\/strong>. They\u2019re keen to make the leap from a simple eSOP to a <a href=\"https:\/\/www.yokogawa.com\/solutions\/products-platforms\/solution-based-software\/optimization\/procedural-automation-exapilot\/\">driver <img decoding=\"async\" class=\" wp-image-7809 alignright\" src=\"https:\/\/www.yokogawa.com\/eu\/blog\/app\/uploads\/sites\/8\/2022\/06\/Exap-Op-300x153.jpg\" alt=\"\" width=\"596\" height=\"304\" \/>assistance system<\/a>. This driver assistance system could be a simple \u201cnavigation\u201d system that churns out driving instructions in either offline or (preferably) online open loop mode alongside the PCS. Parallel to what the operators are doing, the driver assistance system shows what needs to be done next as well as what has already been done. The activities in question are either manually acknowledged or automatically triggered by actual values. Example: The pending activity is to open a valve 50%. With an offline system, the operator would have to manually acknowledge the 50% position after carrying out this activity whereas with an online system, the 50% position is read out automatically and the activity flagged as \u201cdone\u201d. As an automated driving system running in an online closed loop, the assistance system executes all necessary and automated steps independently, for example if it is triggered by a measured value or by the result of a calculation (RTO). The operator is only required to intervene if parts of the procedure, such as communication with the field, are not automated.<\/p>\n<h3><strong>Isn\u2019t that just a sequence? No, it\u2019s not!<\/strong><\/h3>\n<p>No \u2013 because a sequence would be stored in the PCS or another control system. Our driver assistance system collaborates with the <strong>various control systems<\/strong> and takes account of all <strong>relevant players<\/strong> in the procedure. That simplifies <strong>cooperation<\/strong> as well as making it safer and more secure. Thanks to the interaction with a driver assistance system, it\u2019s now practically impossible not to realize that manual valves A, B and C first have to be closed in the field before you set the setpoint for valve V-001 to 50%. The sequence is clear and you can even set a block so that a new setpoint can only be specified on the PCS after something has been switched on the separate hard panel A.<\/p>\n<p><img decoding=\"async\" class=\" wp-image-7805 alignleft\" src=\"https:\/\/www.yokogawa.com\/eu\/blog\/app\/uploads\/sites\/8\/2022\/06\/Exap-Builder-300x156.jpg\" alt=\"\" width=\"585\" height=\"304\" \/>Apart from ease of use, another benefit that has frequently been mooted in discussions about assistance systems such as this is ease of interaction and maintenance. You don\u2019t have to be an expert in PCS or PLC programming to set up, maintain and use our driver assistance system. If I want to make any changes to the startup process, for instance, I can enter them in the <a href=\"https:\/\/www.yokogawa.com\/solutions\/products-platforms\/solution-based-software\/optimization\/procedural-automation-exapilot\/\">driver assistance system<\/a> without going anywhere near the PCS. The system can be expanded with operator know-how at any time, and all changes are documented.<\/p>\n<p><em>A good <\/em><strong><em>driver assistance system<\/em><\/strong><em> is <\/em><strong><em>designed to support the operator<\/em><\/strong><em> and is <\/em><strong><em>independent of the PCS manufacturer<\/em><\/strong><em>. It incorporates the <\/em><strong><em>knowledge<\/em><\/strong><em> which has been built up by the operators into the SOP and <\/em><strong><em>retains<\/em><\/strong><em> it without compromising the PLC\u2019s integrity. It <\/em><strong><em>increases safety<\/em><\/strong><em> while the plant is running and hence improves <\/em><strong><em>productivity<\/em><\/strong><em>.<\/em><\/p>\n<p>And by the way, a driver assistance system may not be an operator training simulator, but in addition to everything mentioned above it can also be used as a training aid in offline open loop mode \u2013 and one that is definitely more \u201cexciting\u201d than reading the operating procedure.<\/p>\n<p><em>END of our four-part series on \u201cAssistance Systems\u201d<\/em><\/p>\n<hr \/>\n<blockquote class=\"wp-embedded-content\" data-secret=\"LgK1VsIh2p\"><p><a href=\"https:\/\/www.yokogawa.com\/eu\/blog\/chemical-pharma\/en\/automation-en\/assistance-systems-3-the-signpost-the-predictor\/\">Assistance systems 3 \u2013 The \u201csignpost\u201d &amp; the \u201cpredictor\u201d<\/a><\/p><\/blockquote>\n<p><iframe class=\"wp-embedded-content\" sandbox=\"allow-scripts\" security=\"restricted\" style=\"position: absolute; clip: rect(1px, 1px, 1px, 1px);\" title=\"&#8220;Assistance systems 3 \u2013 The \u201csignpost\u201d &amp; the \u201cpredictor\u201d&#8221; &#8212; Chemical Pharma Blog\" src=\"https:\/\/www.yokogawa.com\/eu\/blog\/chemical-pharma\/en\/automation-en\/assistance-systems-3-the-signpost-the-predictor\/embed\/#?secret=pwUoePjLjO#?secret=LgK1VsIh2p\" data-secret=\"LgK1VsIh2p\" width=\"500\" height=\"282\" frameborder=\"0\" marginwidth=\"0\" marginheight=\"0\" scrolling=\"no\"><\/iframe><\/p>\n<blockquote class=\"wp-embedded-content\" data-secret=\"DNukpwufzg\"><p><a href=\"https:\/\/www.yokogawa.com\/eu\/blog\/chemical-pharma\/en\/automation-en\/assistance-systems-2-electronic-stability-control\/\">Assistance systems \u2013 2. Electronic stability control<\/a><\/p><\/blockquote>\n<p><iframe class=\"wp-embedded-content\" sandbox=\"allow-scripts\" security=\"restricted\" style=\"position: absolute; clip: rect(1px, 1px, 1px, 1px);\" title=\"&#8220;Assistance systems \u2013 2. Electronic stability control&#8221; &#8212; Chemical Pharma Blog\" src=\"https:\/\/www.yokogawa.com\/eu\/blog\/chemical-pharma\/en\/automation-en\/assistance-systems-2-electronic-stability-control\/embed\/#?secret=PmNYdAM5nw#?secret=DNukpwufzg\" data-secret=\"DNukpwufzg\" width=\"500\" height=\"282\" frameborder=\"0\" marginwidth=\"0\" marginheight=\"0\" scrolling=\"no\"><\/iframe><\/p>\n<blockquote class=\"wp-embedded-content\" data-secret=\"9BE90Tfcec\"><p><a href=\"https:\/\/www.yokogawa.com\/eu\/blog\/chemical-pharma\/en\/automation-en\/assistance-systems-1-our-little-daily-helpers\/\">Assistance systems \u2013 1. Our little daily helpers<\/a><\/p><\/blockquote>\n<p><iframe class=\"wp-embedded-content\" sandbox=\"allow-scripts\" security=\"restricted\" style=\"position: absolute; clip: rect(1px, 1px, 1px, 1px);\" title=\"&#8220;Assistance systems \u2013 1. Our little daily helpers&#8221; &#8212; Chemical Pharma Blog\" src=\"https:\/\/www.yokogawa.com\/eu\/blog\/chemical-pharma\/en\/automation-en\/assistance-systems-1-our-little-daily-helpers\/embed\/#?secret=AqQrhhx0mW#?secret=9BE90Tfcec\" data-secret=\"9BE90Tfcec\" width=\"500\" height=\"282\" frameborder=\"0\" marginwidth=\"0\" marginheight=\"0\" scrolling=\"no\"><\/iframe><\/p>\n<p>&nbsp;<\/p>\n","protected":false},"excerpt":{"rendered":"<p>Today&#8217;s assistance systems are like an &#8220;electronic driving instructor&#8221; who &#8211; not only in tricky situations &#8211; always supports the user with his experience. With a view to the systems, they are driving assistance systems in the truest sense of&hellip; <\/p>\n<p class=\"read-more\"> <a class=\"\" href=\"https:\/\/www.yokogawa.com\/eu\/blog\/chemical-pharma\/en\/assistance-systems-4-retain-knowledge-and-drive-safely\/\"> <span class=\"screen-reader-text\">Assistance systems \u2013 4. Retain knowledge and \u201cdrive\u201d safely<\/span> Read More &raquo;<\/a><\/p>\n","protected":false},"author":125,"featured_media":2481,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_uag_custom_page_level_css":"","site-sidebar-layout":"default","site-content-layout":"","ast-site-content-layout":"","site-content-style":"default","site-sidebar-style":"default","ast-global-header-display":"","ast-banner-title-visibility":"","ast-main-header-display":"","ast-hfb-above-header-display":"","ast-hfb-below-header-display":"","ast-hfb-mobile-header-display":"","site-post-title":"","ast-breadcrumbs-content":"","ast-featured-img":"","footer-sml-layout":"","theme-transparent-header-meta":"","adv-header-id-meta":"","stick-header-meta":"","header-above-stick-meta":"","header-main-stick-meta":"","header-below-stick-meta":"","astra-migrate-meta-layouts":"","footnotes":""},"categories":[56,58],"tags":[438,439,440,441,348,145,146,171,442,443,444,73,291,445,292,78],"coauthors":[],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v20.13 (Yoast SEO v20.13) - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>Assistance systems \u2013 4. Retain knowledge and \u201cdrive\u201d safely - Chemical Pharma Blog<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.yokogawa.com\/eu\/blog\/chemical-pharma\/en\/assistance-systems-4-retain-knowledge-and-drive-safely\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Assistance systems \u2013 4. Retain knowledge and \u201cdrive\u201d safely\" \/>\n<meta property=\"og:description\" content=\"Today&#039;s assistance systems are like an &quot;electronic driving instructor&quot; who - not only in tricky situations - always supports the user with his experience. With a view to the systems, they are driving assistance systems in the truest sense of&hellip;  Assistance systems \u2013 4. 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